Miller BIG BLUE 600D User manual

Miller BIG BLUE 600D User manual
 January 1990 FORM: OM-481
Effective With Serial No. KA748844
ler.
MODEL: Big Blue" 600D
'OWNER’S MANUAL
IMPORTANT: Read and understand the entire contents of this manual, with | MILLER ELECTRIC Mfg. Co.
special emphasis on the safety material throughout the manual, before A Miller Group Ltd., Company
installing, operating, or maintaining this equipment. This unit and these PO. Box 1070
instructions are for use only by persons trained and experienced in the safe Appleton, WI 54912 USA
operation of welding equipment. Do not allow untrained persons to install, Tel. 414-734-9821
operate, or maintain this unit. Contact your distributor if you do not fuily
understand these instructions.
SC-134 686 PRINTED INU.SA
- =
©
LIMITED WARRANTY
EFFECTIVE: FEBRUARY 1, 1990
LIMITED WARRANTY -— Subject to the terms and conditions
hereof, Miller Electric Mfg. Co., Appleton, Wisconsin warrants
to its Distributor/Dealer that ali new and unused Equipment fur-
nished by Miller is free from defect in workmanship and material
as of the time and place of delivery by Miller. No warranty is
made by Miller with respect to engines, trade accessories or
other items manufactured by others. Such engines, trade ac-
cessories and other items are sold subject to the warranties of
their respective manufacturers, if any. All engines are warran-
tied by their manufacturer fortwo years from date of original pur-
chase, except Deutz engines which have a one year, 2000 hour
warranty.
Except as specified below, Miller's warranty does not apply to
components having normal useful life of less than one (1) year,
such as spot welder tips, relay and contactor points, MILLER-
MATIC parts that come in contact with the welding wire includ-
ing nozzies and nozzle insulators where failure does not result
from defect in workmanship or material.
Miller shall be required to honor warranty claims on warranted
Equipmentin the event of failure resulting from a defect within
the foliowing periods from the date of delivery of Equipment to
the original user:
1. Arc weiders, power sources, robots, and ........ 1 year
components
2. Loadbanks .......... LiL 1 year
3. Original main power rectifiers ............... 3 years
{labor — 1 year only)
4. All welding guns, feeder/guns and torches .... 90 days
5. All other Millermatic Feeders ................. 1 year
6. Replacement or repair parts, exclusive of labor. 60 days
7. Batteries .......... 2000 кк... E months
provided that Miller is notified in writing within thirty (30) days of
the date of such failure.
As a matter of general policy only, Miller may honor claims
submitted by the original user within the foregoing periods.
e
This warranty supersedes all previous MILLER warranties and is exclusive with no other guarantees or warranties expressed or implied.
Inthe case of Miller's breach of warranty or any other duty with
respect to the quality of any goods, the exclusive remedies
therefore shallbe, at Miller's option (1) repair or (2) replacement
or, where authorized in writing by Miller in appropriate cases, (3)
the reasonable cost of repair or replacement at an authorized
Miller service station or (4) payment of or credit for the purchase
price (less reasonable depreciation based upon actual use)
upon return of the goods at Customers risk and expense.
MILLER's option of repair or replacement willbe F.C.B., Factory
at Appleton, Wisconsin, or F.O.B. at a MILLER authorized serv-
ice facility, therefore, no compensation for transportation costs
of any kind will be allowed. Upon receipt of notice of apparent
defect or failure, Miller shall instruct the claimant on the war-
ranty claim procedures to be followed.
ANY EXPRESS WARRANTY NOT PRCVIDED HEREIN
AND ANY IMPLIED WARRANTY, GUARANTY OR REPRE-
SENTATION AS TO PERFORMANCE, AND ANY REMEDY
FOR BREACH OF CONTRACT WHICH, BUT FOR THIS PRO-
VISION, MIGHT ARISE BY IMPLICATION, OPERATION OF
LAW, CUSTOM OF TRADE OR COURSE OF DEALING, IN-
CLUDING ANY IMPLIED WARRANTY OF MERCHAN-
TABILITY OR OF FITNESS FOR PARTICULAR PURPOSE,
WITH RESPECT TO ANY AND ALL EQUIPMENT FUR-
NISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY
MILLER.
EXCEPT AS EXPRESSLY PROVIDED BY MILLER IN
WRITING, MILLER PRODUCTS ARE INTENDED FOR ULTI-
MATE PURCHASE BY COMMERCIAL/INDUSTRIAL USERS
AND FOR OPERATION BY PERSONS TRAINED AND EXPE-
RIENCED IN THE USE AND MAINTENANCE OF WELDING
EQUIPMENT AND NOT FOR CONSUMERS OR CON-
SUMER USE. MILLER'S WARRANTIES DO NOT EXTEND
TO, AND NO RESELLER IS AUTHORIZED ТО EXTEND
MILLER'S WARRANTIES TO, ANY CONSUMER.
April 21, 1992 FORM: OM-481
ERRATA SHEET
After this manual was printed, refinements in equipment design occurred. This sheet lists exceptions
to data appearing later in this manual.
AMENDMENT TO SECTION 4 ~ INSTALLATION OR RELOCATION
Amend Figure 4-5. Terminal Strip Information
External Devices/
Welding Power Supply
Connections
24VAC 10A MAX
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24VAC a
0-1 k&2 2w |
potentiometer
MAXI
24VAC Contactor Controi R
0-10VDC Reference
@ CS |
Control Circuit Common
DO | PCB
0-10VDC Output Level Command
e FO!
Circuit Common ©
GO | 7
15VAC 10A МАХ
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Equipment Ground
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5VAC Contactor Control
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115VAC |
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5-133 149
Figure 4-5. Termina! Strip Information Label
AMENDMENT TO SECTION 5 - AUXILIARY POWER
IMPORTANT: Delete all references to the standard 240V 13A duplex receptacle. This unit is equipped with two 120V
duplex receptacles, and the 240V 13A duplex receptacle is only available as an option.
Amend Section 5-2B. AUXILIARY POWER RECEPTACLES: 120 Volts AC Duplex Receptacle Specifications
120V 26A NAC
The 120V 26A duplex receptacies provide 60 Hz single-phase power for use while welding. Up to 15 amperes can be
drawn from either halfofa 120V duplex receptacie; however, the total load on the dupiex receptacies cannot exceed 26
amperes. The combined continuous load of all receptacies cannot exceed the KVA/kW rating of the generator.
Ai
Amend Section 5-2C. AUXILIARY POWER RECEPTACLES: 240 Volts AC Duplex Receptacle Specifications to read
as follows: Optional 240 Volts AC Duplex Receptacle Specifications
240V 13A NAC
Rated auxiliary power output is 3 kVA/kW of 240 volts ac 60 Hz at the optional 240V 13A duplex receptacle. The power
available from this receptacle is dependent on the amount of power being drawn from the 120V 15A duplex receptacie.
Up to 13 amperes can be drawn from either half of the 240V 13A receptacle. The combined continuous load of all
receptacles cannot exceed the KVA/KW rating of the generator.
Amend Section 5-2E. AUXILIARY POWER RECEPTACLES: Protection. Amend the second paragraph to read as
follows:
Circuit breakers CB1 protects 120V 15A duplex receptacle RC1 and CB2 protects 120V 15A duplex receptacle RC2
from overload and fault conditions.
If unit is equipped with optional 240V 13A duplex receptacle RC1, both CB1 and CB2 protect RC1, and each breaker
also protects one half of 120V 15A duplex receptacle ВС2.
If a duplex receptacle is overloaded, the respective circuit breaker(s) opens, and the receptacle(s) becomes
inoperative. See Section 9-3 for resetting procedures.
AMENDMENT TO SECTION 9 - TROUBLESHOOTING
Amend section 9-3A. OVERLOAD PROTECTION: Circuit breakers CB1 and CB2
WARNING: ELECTRIC SHOCK can kill.
e Do not touch live electrical parts.
e Stop engine, and disconnect negative (-) battery cable from battery before inspecting, maintaining, or
servicing. |
MOVING PARTS can cause serious injury.
* Keep away from moving parts such as fans, belts, and rotors.
HOT ENGINE PARTS can cause severe burns.
o Wear protective gloves and clothing when working on a hot engine.
INCORRECT FUSE can damage unit.
e Use only replacement fuse of same size, type, and rating (see Parts List).
Circuit breakers CB1 and CB2 protect auxiliary power duplex receptacles RC1 and RC2 from overload. CB1 and CB2
are located behind the front panel lower access door, above the duplex receptacles RC1 and RC2 (see Figure 6-1). if
CB1 opens, output to 120V receptacle RC1 stops. if CB2 opens, output to 120V receptacle RC2 stops. If unit is
+. equipped with optional 240V duplex receptacle RC1, when either CB1 or CB2 opens, output to both halves of RC1 and
- One half of 120V receptacle RC2 stops.
— A CB1 and/or CB2 opens, locate and correct problem, and manually reset breaker(s).
IMPORTANT: /f a breaker opens when use of auxiliary equipment begins, a fault is probably present in the auxiliary
equipment. If a breaker opens after prolonged equipment use, an overload condition probably exists.
AMENDMENT TO SECTION 10 —- ELECTRICAL DIAGRAMS
Amend Diagram 10-1. Circuit Diagram (see Pages 3, 4 and 5 on this Errata Sheet)
Amend Diagram 10-2. Wiring Diagram (see Pages 6, 7, 8 and 9 on this Errata Sheet)
Amend Diagram 10-3. Circuit Diagram For Field Current Regulator Circuit Board PC1 (see Page 10 on this Errata
Sheet)
OM-481 Page 2
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Circuit Diagram No. SD-131 087-D
OM-481 Page 3
Diagram 10-1. Circuit Diagram Effective With Serial No. KA748844 Thru KB073800
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Diagram 10-1. Circuit Diagram Effective With Serial No. KB073801 And Following
OM-481 Page 4
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TERMINAL NEGATIVE POSITIVE
Circuit Diagram No. SD-145 039-A
OM-481 Page 5
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Diagram 10-2. Wiring Diagram Effective With Serial No. KA748844 Thru KB073800
OM-481 Page 6
OIL
PRESS
OIL
TEMP
GND.STUD
SLIP RINGS
FUEL LEVEL
SENCINS UNIT
Wiring Diagram No. SD-132 264-C
OM-481 Page 7
GND. STRIP
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Diagram 10-2. Wiring Diagram Effective With Serial No. KB073801 And Following
OM-481 Page 8
DIL OIL
PRESS TEMP
J7A[SR3-C/AL)
GND. STUD
SLIP RINGS
425(TE4-B)
FUEL LEVEL
SENCING UNIT
Wiring Diagram No. $D-145 037-A
OM-481 Page 9
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Circuit Diagram No. SB-115 028-B
Diagram 10-3. Circuit Diagram For Field Current Regulator Circuit Board PC1
OM-481 Page 10
AMENDMENT TO SECTION 11 - PARTS LIST
Amend Parts List as Follows:
Dia. Pari Replaced Е
++ Mkgs. No. With Description Quantity
VD 121 699 .. 121699 .. SPACE, (gtychg) .............-eresereererer ere 3
42- 111112101000 Added .. 089256 .. CLAMP stlcush1.750dia ................. oon, 1
42-3 ........... 087341 .. 087 341 .. BUMPER, (atychg) . ....... coi, 2
42- LL Lau Added .. 134771 .. PLUG, protective .640sq (used on engine door) ......... 2
NE 010143 .. 010014 .. CLAMP sil cush .750día x .203mtg hole ............... 1
43-64 .......... 081 646 .. 081646 .. FITTING, (gty chg) (Eff w/KB0O67430) ................. 1
43-65 .......... 010678 .. 145281 .. FITTING, hose brs barbed elb M 3/8tbg x 1/4NPT
(Eff w/KB067430) ............—eoeereererecererea.. 1
43-71 .......... 073432 .. 073433 .. FITTING, brs barbed M 3/16tbg x 1/4NPT
(Eff w/KB158251) i re ea a a aa see 1
43-72 .......... 010869 ... Deleted .. Eff w/KB158251
43-78 SR3 ... 131805 .. 142505 .. RECTIFIER, siOph 300A .......................... 1
43- 1.121112 4 40 Added .. 145 023 .. BRACKET, mtg strip term (Eff w/KB073801) ........... 1
43- 2........... Added .. 145035 .. INSULATOR, strip term (Eff w/KB073801) ............. 1
43- 4T ..... Added .. 038621 .. BLOCK, term 30A 4P (Eff w/KB073801) ............... 1
43- 22... .... Added .. 038620 .. LINK, jumper term blk 30A (Eff w/KB073801) ........... 2
“N Added .. 146240 .. BRACKET, head shield (Eff w/KB0S5948) ............. 1
45-11... $1 .... 128 019 .. 1448641 .. SWITCH, ignition Sposn .............. iin. 1
CO 119482 .. 146358 .. SENDER, fuel gauge (Eff w/KB099224) ............... 1
47-9 61,2 ... 080894 .. 136736... CAPACITOR ........... .emerendearer ere A 2
47-13 . CB1,2... 053283 .. 139266 .. CIRCUIT BREAKER, man reset 1P 15A 250VAC ....... 2
47-14 RC2 ... 604103 ... Deleted .. (Eff w/KBO73801)
47-15 .......... 039864 .. 039864 .. RECEPTACLE, (qty chg added RC2)
(Eff w/KBO73801) 1.000000 a eee a ee a eee 00 2
47-17 RC3 ... 109769 .. 143976 .. RECEPTACLE w/SOCKETS, (Eff w/KC211335)
(consisting of) ......... oi наен о 1
ee ee ee ea 079534 .... TERMINAL, female 1skt 18-14 wire ................ 14
Cee 100766 .. 134 734 .. HOUSING, term piug pistc 14cont shell sz 20
Amp 213571-2
ee 109770 .. 134731 .. TERMINAL, male 1 pin 18-14 wire Amp 213603-1
Sn 116964 .. (079739 .. CLAMP cable strain relief sz 17 Amp 206322-2
47-21 C3-9,11 132661 .. 138695 .. CAPACITOR ..... ee 8
47-27 .......... 132276 .. 145043... PLATE, ident control rating lower (Eff w/KB073801) ...... 1
A 110089 .. CABLE, interconnecting (consistingof) ............... 1
ee eee 094 481 .... PLUG, 14 pin MS-3106A-20-27P (Prior to KC224994) .. 1
Ce RK KK 141162 .... HOUSING PLUG & PINS, (Eff w/KC224994)
(consisting of) .......2020200 0010114 ae ae a a ae a ea ee 1
Ce eee eee aa 134731 ...... TERMINAL, male 1 pin 18-14wire ................ 14
PS 079739 ...... CLAMP, cable strain relief sz 17 .703 max cable OD .. 1
ee RA 039734 .... CLAMP, cable AN-3057-12 (Prior to KC224994) ....... 1
adaaonanendrararaearocore, 600 343 .... CABLE, port No. 16 5/c (order by ft) ................ 1f
andado aorenenronadvecreos 052 654 .... RECEPTACLE, 5skt 97-3101A-168-85.............. 1
ee ere eae 039685 .... CLAMP, cable AN-3057-8 ............... cco 1
48-10 .. PC2 ... 114832 . +145 207 .. CIRCUIT CARD, voltage regulator ................... 1
. 51- .. 02-79,
11,13 ... 073739 .. 122723 .. CAPACITOR, cer mono .1uf 5S0VDC ...............e_. 9
. Si- . VR1 ... 081 832 .. 083772... IC, linear 7815 .......e.rererarveraoare nreaeare a 1
52-8 .........,. 044 755 .. *151 299 .. BRUSH, contact elect cirg .375 X .750 ........._ e.ee—_. 1
52-5 ........... 018665 .. 152044... CAP, holder brush brs .............eserevrrerermer. 1
52-8 .......... +130 989 .. 140096 .. STATOR, generators (Eff w/KA892252) ............... 1
52-14 .......... 117009 .. 145021 .. STATOR, excitor (Eff w/KB0O73801) .................. 1
“First digit represents page no — digits following dash represent item no.
*Recommended Spare
Parts.
+All components for PC2 remain the same.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-481 Page 11
== =
OM-481 — 1/90
RECEIVING-HANDLING
Before unpacking equipment, check carton for any dam-
age that may have occurred during shipment. File any
claims for loss or damage with the delivering carrier.
Assistance for filing or settling claims may be obtained
from the distributor and/or the equipment manutactur-
Use the following spaces to record the Model Designa-
tion and Serial or Style Number of your unit. The infor-
mation is located on the data card or the nameplate.
Model
er's Transportation Department.
р Р Serial or Style No.
When requesting information about this equipment, al-
ways provide the Model Description and Serial or Style
Number,
Date of Purchase
TABLE OF CONTENTS
SER SERRE EE EERE EE RR RE
Section No. Page No.
SECTION 1 — SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
1-1. Introduction... erersararerdiocec 1
1-2. General Precautions .......... citi. 1
1-3. Arc Welding ee eee 4
1-4. Standards Booklet Index ........ cc. viii... 5
SECTION 2 — SAFETY PRECAUTIONS AND SIGNAL WORDS
2-1. General Information And Safety ................ 022... ... 6
2-2. Safety Alert Symbol And Signal Words .............eo_._eeeoc.. 6
SECTION 3 — SPECIFICATIONS
3-1. Voit-Ampere Curves .........200 04401114 ee a a a a a aa aa aa ae 8
3-2. Duty Cycle ......11 LL LL LL Va Lea A a La ae Là 8
3-3. Description .......11200 4410044 0 44e a ea a ee La 4 a ea ea aa à 8
SECTION 4 — INSTALLATION OR RELOCATION
4-1. Location ......1222010 ee ee 9
4-2. Exhaust Extension Installation ........................ FT 10
4-3. Connecting The Battery ........ i. 10
4-4. Fuel ....... LL La 4 LL ALL LA a LA LA 4 aa a Le a aa 10
45. Lubrication ......202 000044 a aa da a 4 a a a A 4e a a a 4 AA a aa a a aa a 10
4-6. Equipment Grounding Terminal ee 11
4-7. Weld Quiput Connections ........... cian. 11
4-8. Remote Control Connections . ........ ei. 12
4-9. Ether Starting Aid (Optional) ....................... ci. .... 14
4-10. Locking Control Panel Cover (Optional) ...................... 14
SECTION 5 - AUXILIARY POWER
5-1. General erdrenoecareoronaerearararmemara 15
5-2. Auxiliary Power Receptacles ....... i. 15
. me Ba
Section No. Page No.
SECTION 6 — OPERATOR CONTROLS
6-1. Range Switch ........ ereceriradioerorooerei.. 16
6-2. Amperage & Voltage Adjustment Control . . .................... 17
6-3. Engine Control Switch ................. .. ee .endooeaaca 18
6-4. Constant Current/Constant Voltage (CC/CV) Switch ............. 18
6-5. Remote Amperage & Voltage Control Switch .................. 18
6-6. Output (Contactor) Switch .................. ...... c........ 18
6-7, Service Engine Air Cleanerindicator ......................... 19
6-8. Cooling System/Alternator Indicator ......................... 19
6-9. HourMeter ...... e. eenearoroenoararoa orar. 19
6-10. Fuel Gauge ........ RR Rae 1 ee 19
6-11. Low Oil Pressure/High Coolant Temperature
Shutdown System Switch ...........ee..eeeeadarearororaa 19
6-12. Oil Temperature Gauge/Switch ............... naar. 19
6-13. Oil Pressure Gauge/Switch ................... ea 19
6-14. Battery Ampere Gauge ............ 0000 anar 19
6-15. Meters 000... n0erv0decearoaorecononmarceo 19
6-16. Ether Starting Aid (Optional) ................—...2 0... aa 20
SECTION 7 —- SEQUENCE OF OPERATION
7-1. Shieided Metal Arc Welding (SMAW) ........................ 20
7-2. Gas Metal Arc (GMAW) And Flux Cored Arc Welding (FCAW) ..... 21
7-3. Submerged Arc Welding (SAW) ................... reee. 21
7-4. Air Carbon Arc Cutting And Gouging (AAC) ................—... 22
7-5. Auxiliary Power Operation ............... i. 22
7-6. Starting The Engine ................ e eaorereraao, 22
7-7. Stopping The Engine .................— Ce eee 23
SECTION 8 — MAINTENANCE
8-1. RoutineMaintenance ................ .... 0. iia. in. 23
8-2. Air Cleaner Service ............... ererececec. 24
8-3. Fuel/Water Separator And Sludge Drain Plug .................. 26
8-4. Fuel Fler... RR RR RR a 26
8-5. CheckingEngineBelt...................... .. . . ... .. . ..... 26
8-6. Battery Replacement Procedure ...................cc.. ..... 27
8-7. Maintenance-Free Battery Charging . ........................ 27
8-8. GOVEINOr ..... ee 28
8-9. Engine Speed Adjustments .................... кк. 28
8-10. Replacing Engine Belt ................ aaa 28
8-11. Brushes And Slip Rings ....................... rreceac. 29
8-12. Ether Starting Aid (Optional) ............................... 29
8-13. Servicing The Spark Arrestor (Optional) ...................... 29
SECTION 9 — TROUBLESHOOTING
9-1. General ...... Le LL Aa LA Aa La 30
9-2. Booster Battery Jump Starting ............... e... 30
9-3. €¿Overoad Protection .............. 0. ii. 31
9-4. Circuit Board Handling Precautions ........................ .. 31
9-5. Troubleshooting .............. ererereerecaaca o. 31
Section No.
SECTION 10 — ELECTRICAL. DIAGRAMS
Diagram 10-1. Circuit Diagram. ........... iii.
Diagram 10-2. Winng Diagram... RR 122
Diagram 10-3. Circuit Diagram For Field Current Regulator
Circuit Board PC1 .............. 0.220.000 0e
Diagram 10-4. Circuit Diagram For CV Regulator Circuit Board PC2 ......
SECTION 11 — PARTS LIST
Figure 11-1. Main Assembly ..........r.—e-—e—m—eeredecerarerercereaa,
Figure 11-2. Panel Front w/Components .............eo_.eoocxceovoreoo
Figure 11-3. Front-Lower w/Components ..............—eeeeceoeaoaoo
Figure 11-4. Control Box RR RR a a aa aa ae
Figure 11-5. Circuit Card, Voltage Regulator . . . ......................
Figure 11-6. Circuit Card, Field Current Regulator PC1 ................
Figure 11-7. Generator RR RK a ane
Optional Equipment ..............eo——.—.—rresrecrrrcererecerecare.
LIST OF CHARTS AND TABLES
Table 3-1. Welding Generator Specifications .........................
Chart 3-1. Voll-Ampere CUIVesS ...... coo ee eee inna
Chart 3-2. Duty Cycle ......... i eee
Chart 4-1, Fuel Consumption Curve ...........—.e.e0a.rvrerereo na.
Table 4-1. Weld Cable Size .................. ia
Chart 5-1. AC Power Curve For 120 And 240 Volts Duplex Receptacles
(No Weld Load Condition) ....................—.900-.
Tabie 7-1. Suggested Electrode Diameter For Amperage Range
(AAC Only) ........... 2... ea A ee ee a a a a A aa a a a a ane
Table 8-1. Maintenance Schedule ................... . . . . . . .... ...
Table 8-2. Air Cleaner Service . .. ....... iii
Table 9-1. Weld/Power Troubleshooting ............... cc... .....
Table 9-2. Auxiliary Power Troubleshooting .........................
Table 9-3. Engine Troubleshooting... ............ un...
Page No.
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40
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46
48
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- " E,
EU
SECTION 1 — SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE
DEE EE CES
1-1. INTRODUCTION
We learn by experience. Learning safety through per-
sonal experience, like a child touching a hot stove is
harmful, wasteful, and unwise. Let the experience of oth--
ers teach you.
Safe practices developed from experience in the use of
welding and cutting are described in this manual. Re-
search, development, and field experience have
evolved reliable equipment and safe installation, opera-
tion, and servicing practices. Accidents occur when
equipment is improperly used or maintained. The rea-
son for the safe practices may not always be given.
Some are based on common sense, others may require
technical volumes to explain. lt is wiser to follow the
rules.
Read and understand these safe practices before at-
tempting to install, operate, or service the equipment.
Comply with these procedures as applicable to the par-
ticular equipment used and theirinstruction manuals, for
personal safety and for the safety of others.
Failure to observe these safe practices may cause seri-
ous injury or death. When safety becomes a habit, the
equipment can be used with confidence.
These safe practices are divided into two Sections:
1-General Precautions, common to arc welding and cut-
ting; and 2-Arc Welding (and Cutting) (only).
Reference standards: Published Standards on safety
are also available for additional and more complete pro-
cedures than those given in this manual. They are listed
in the Standards Index in this manual. ANS! Z49.1 is the
most complete.
The National Electrical Code, Occupational Safety and
Health Administration, local industrial codes, and local
inspection requirements also provide a basis for equip-
ment installation, use, and service.
1-2. GENERAL PRECAUTIONS
Different arc welding processes, electrode alloys,
and fluxes can produce different fumes, gases, and
radiation levels. In addition to the information in this
manual, be sure to consult flux and electrode manu-
facturers Material Safety Data Sheets (MSDSs) for
specific technical data and precautionary measures
concerning their material.
A. Burn Prevention
Wear protective clothing-gauntlet gloves designed for
use in welding, hat, and high safety-toe shoes. Button
shirt collar and pocket flaps, and wear cuffless trousers
to avoid entry of sparks and slag.
Wear helmet with safety goggles and glasses with side
shields underneath, appropriate filter lenses or plates
(protected by clear cover glass). This is a MUST for
welding or cutting, (and chipping) to protect the eyes
from radiant energy and flying metal. Replace cover
glass when broken, pitted, or spattered. See 1-3A.2.
Avoid oily or greasy clothing. A spark may ignite them.
Hot metal such as electrode stubs and workpieces
should never be handled without gloves.
Medical first aid and eye treatment. First aid facilities and
a qualified first aid person should be available for each
shift unless medical facilities are close by for immediate
treatment of flash burns of the eyes and skin burns.
Ear plugs should be worn when working on overhead or
in a confined space. A hard hat should be wom when
others work overhead.
Flammable hair preparations should not be used by per-
sons intending to weld or cut.
B. Toxic Fume Prevention
Severe discomfort, illness or death can result from
fumes, vapors, heat, or oxygen enrichment or depletion
that welding (or cutting) may produce. Prevent themwith
adequate ventilation as described in ANSI Standard
249.1 listed in Standards Index. NEVER ventilate with
oxygen.
Lead -, cadmium -, zinc -, mercury -, and beryllium-bear-
ing and similar materials, when welded (or cut) may pro-
duce harmful concentrations of toxic fumes. Adequate
local exhaust ventilation must be used, or each personin
the area as well as the operator must wear an air-sup-
plied respirator. For beryilium, both must be used.
Metals coated with or containing materials that emittoxic
fumes should not be heated unless coating is removed
from the work surface, the area is well ventilated and, if
necessary, while wearing an air-supplied respirator.
Work in a confined space only while it is being ventilated
and, if necessary, while wearing an air-supplied respira-
tor.
Gas leaks in a confined space should be avoided.
Leaked gas in large quantities can change oxygen con-
centration dangerously. Do not bring gas cylinders into a
confined space.
Leaving confined space, shut OFF gas supply at source
to prevent possible accumulation of gases inthe space if
downstream vaives have been accidentaliy opened or
left onen. Check to be sure that the space is safe before
re-entering it. |
Vapors from chlorinated solvents can be decomposed
by the heat of the arc (or flame) to form PHOSGENE, a
highly toxic gas, and other lung and eye irritating prod-
ucts. The ultraviolet (radiant) energy of the arc can also
decompose trichloroethylene and perchioroethylene
vapors to form phosgene. DO NOT WELD or cut where
solvent vapors can be drawn into the welding or cutting
atmosphere or where the radiant energy can penetrate
OM-481 Page 1
- a,
to atmospheres containing even minute amounts of
trichloroethylene or perchloroethylene.
C. Fire and Explosion Prevention
Causes of fire and explosion are: combustibles reached
by the arc, flame, flying sparks, hot slag or heated mate-
rial; misuse of compressed gases and cylinders; and
short circuits. |
BE AWARE THAT flying sparks or falling slag can pass
through cracks, along pipes, through windows or doors,
and through wall or floor openings, out of sight of the
goggled operator. Sparks and slag can fly 35 feet.
To prevent fires and explosion:
Keep equipment clean and operable, free of oil, grease,
and (in electrical parts) of metallic particles that can
cause short circuits.
If combustibles are in area, do NOT weld or cut. Move
the work if practicable, to an area free of combustibles.
Avoid paint spray rooms, dip tanks, storage areas, venti-
lators. if the work cannot be moved, move combustibles
at least 35 feet away out of reach of sparks and heat; or
protect against ignition with suitable and snug-fitting,
fire-resistant covers or shields.
Walls touching combustibles on opposite sides should
not be welded on (or cut). Walls, ceilings, and floor near
work should be protected by heat-resistant covers or
shields.
Fire watcher must be standing by with suitable fire extin-
guishing equipment during and for some time afterweld-
ing or cutting if:
a. appreciable combustibles (including building
construction) are within 35 feet
b. appreciable combustibles are further than 35
feet but can be ignited by sparks
C. openings (concealed orvisible)infloors orwalls
within 35 feet may expose combustibles to
sparks
d. combustibles adjacent to walls, ceilings, roofs,
or metal partitions can be ignited by radiant or
conducted heat.
Hot work permit should be obtained before operation to
ensure supervisor's approvalthat adequate precautions
have been taken.
Aîter work is done, check that area is free of sparks,
glowing embers, and flames.
An empty container that held combustibles, or that can
produce flammable or toxic vapors when heated, must
never be welded on or cut, uniess container has first
beencleaned as described in AWS Standard A6.0, listed
7 in Standards index.
Thisincludes: athorough steamor caustic cleaning (ora
solvent or water washing, depending on the combusti-
ble's solubility) followed by purging and inerting with ni-
trogen or carbon dioxide, and using protective equip-
OM-481 Page 2
ment as recommended in A6.0. Waterfilling just below
working level may substitute for inerting.
A container with unknown contents should be cleaned
(see preceding paragraph). Do NOT dependonsense of
smell or sight to determine if it is safe to weld or cut.
Hollow castings or containers must be vented before
welding or cutting. They can explode.
Explosive atmospheres. Never weld or cut where the air
may contain flammable dust, gas, or liquid vapors (such
as gasoline).
D. Compressed Gas Equipment
Standard precautions. Comply with precautions in this
manual, and those detailed in CGA Standard P-1, SAFE
HANDLING OF COMPRESSED GASES IN CYLIN-
DERS, listed 11 in Standards Index.
1. Pressure Regulators
Regulator relief valve 1s designed to protect only the
regulator from overpressure; it is not intended to protect
any downstream equipment. Provide such protection
with one or more relief devices.
Never connect a regulator to a cylinder containing gas
other than that for which the regulator was designed.
Remove faulty regulatorfrom service immediately for re-
pair (first close cylinder valve). The following symptoms
indicate a faulty regulator:
L eaks-if gas leaks externally.
Excessive Creep-if delivery pressure continues to rise
with downstream valve closed.
Faulty Gauge-if gauge pointer does not move off stop pin
when pressurized, nor returns to stop pin after pressure
release.
Repair. Do NOT attempt to repair. Send faulty regulators
for repair to manufacturer's designated repair center,
where special techniques and tools are used by trained
personnel.
2. Cylinders
Cylinders must be handled carefully to prevent leaks
and damage to their walls, valves, or safety devices:
Avoid electrical circuit contact with cylinders including
third rails, electrical wires, or welding circuits. They can
produce short circuit arcs that may lead to a serious acci-
dent. (See 1-3C.)
ICC or DOT marking must be on each cylinder. it is an
assurance of safety when the cylinder is properly han-
dled.
Identifying gas content. Use only cylinders with name of
gas marked on them; do not rely on color to identify gas
content. Notify supplier if unmarked. NEVER DEFACE
or aiter name, number, or other markings on a cylinder. It
is illegal and hazardous.
Empties: Keep valves closed, replace caps securely;
mark MT; keep them separate from FULLS and return
promptly.
Prohibited use. Never use a cylinder or its contents for
other than its intended use, NEVER as a support or
roller.
Locate or secure cylinders so they cannot be knocked
over.
Passageways and work areas. Keep cylinders clear of
areas where they may be struck.
Transporting cylinders. With a crane, use a secure sup-
port such as a platform orcradle. Do NOT lift cylinders off
the ground by their valves or caps, or by chains, slings,
or magnets.
Do NOT expose cylinders to excessive heat, sparks,
slag, and flame, etc. that may cause rupture. Do not ai-
low contents to exceed 130°F. Cool with water spray
where such exposure exists.
Protect cylinders particularly valves from bumps, falls,
falling objects, and weather. Replace caps securely
when moving cylinders.
Stuck valve. Do NOT use a hammer orwrenchto open a
cylinder valve that can not be opened by hand. Notify
your supplier.
Mixing gases. Never try to mix any gases in a cylinder.
Never refill any cylinder.
Cylinderfittings should never be modified or exchanged.
3. Hose
Prohibited use. Never use hose otherthan that designed
for the specified gas. A general hose identification rule
IS: red forfuel gas, green for oxygen, and black for inert
gases.
Use ferrules or clamps designed for the hose (not ordi-
nary wire or other substitute) as a binding to connect
hoses to fittings.
No copper tubing splices. Use only standard brass fit-
tings to splice hose.
Avoid long runs to prevent kinks and abuse. Suspend
hose off ground to keep it from being run over, stepped
on, or otherwise damaged.
Coil excess hose to prevent kinks and tangles.
Protect hose from damage by sharp edges, and by
sparks, slag, and open flame.
Examine hose regularly for leaks, wear, and loose con-
nections. Immerse pressured hose in water; bubbles in-
dicate leaks.
Repair leaky or worn hose by cutting area out and splic- .
ing (1-203). Do NOT tape.
4. Proper Connections
Clean cylinder valve outlet of impurities that may clog
orifices and damage seats before connecting regulator.
Except for hydrogen, crack valve momentarily, pointing
outlet away from people and sources of ignition. Wipe
with a clean lintless cloth.
Match regulator to cylinder. Before connecting, check
that the regulator label and cylinder marking area, and
thatthe reguiator inlet and cylinder outlet match. NEVER
CONNECT a regulator designed for a particular gas or
gases to a cylinder containing any other gas.
Tighten connections. When assembling threaded con-
nections, clean and smooth seats where necessary.
Tighten. if connection leaks, disassemble, clean, and
retighten using property fitting wrench.
Adapters. Use a CGA adapter (available from your sup-
plier) between cylinder and regulator, if one is required.
use two wrenchesto tighten adapter marked RIGHT and
LEFT HAND threads.
Regulatoroutlet (orhose) connections may be identified
by right hand threads for oxygen and left hand threads
(with grooved hex on nut or shank) for fuel gas.
5. Pressurizing Steps:
Drain reguiator of residual gas through suitable vent be-
fore opening cylinder (or manifold valve) by turning ad-
justing screw in (clockwise). Draining prevents exces-
sive compression heat at high pressure seat by allowing
seat to open on pressurization. Leave adjusting screw
engaged slightly on single-stage regulators.
Stand to side of regulator while opening cylinder valve.
Open cylinder valve slowly so that regulator pressure in-
creases slowly. When gauge is pressurized (gauge
reaches regulator maximum) leave cylinder valve in fol-
lowing position: Foroxygen, and inert gases, open fully
to seal stem against possible ieak. For fuel gas, open to
less than one turn to permit quick emergency shutoff.
Use pressure charts (available from your supplier) for
safe and efficient, recommended pressure settings on
regulators.
Check for leaks on first pressurization and regularly
there-after. Brush with soap solution (capfullof Ivory Lig-
uid* or equivalent per gallon of water). Bubbles indicate
leak. Clean off soapy water after test; dried soap is com-
bustible.
E. User Responsibilities
Remove leaky or defective equipment from service im-
mediately for repair. See User Responsibility statement
in equipment manual.
F. Leaving Equipment Unattended
Close gas supply at source and drain gas.
G. Rope Staging-Support
Rope staging-support should not be used for welding or
cutting operation; rope may burn.
*Trademark of Proctor & Gamble.
OM-481 Page 3
ey
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1-3. ARC WELDING
Comply with precautions in 1-1, 1-2, and this section.
Arc Welding, properly done, is a safe process, but a
careless operator invites trouble. The equipment carries
high currents at significant voltages. The arc is very
bright and hot. Sparks fly, fumes rise, ultraviolet and in-
frared energy radiates, weldments are hot, and com-
pressed gases may be used. The wise operator avoids
unnecessary risks and protects himself and others from
accidents. Precautions are described here and in stan-
dards referenced in index.
A. Burn Protection
Comply with precautions in 1-2.
The welding arc is intense and visibly bright. Its radiation
candamage eyes, penetrate lightweight clothing, reflect
from light-colored surfaces, and burn the skin and eyes.
Skin burns resemble acute sunburn, those from gas-
shielded arcs are more severe and painful. DON'T GET
BURNED; COMPLY WITH PRECAUTIONS.
1. Protective Clothing
Wear long-sleeve clothing (particularly for gas-shieided
arc) in addition to gloves, hat, and shoes (1-2A). As nec-
essary, use additional protective clothing such as
leather jacket or sleeves, flame-proof apron, and fire-re-
sistant leggings. Avoid outer garments of untreated cot-
ton.
Bare skin protection. Wear dark, substantia! clothing.
Button coliar to protect chest and neck and button pock-
ets to prevent entry of sparks.
2. Eye and Head Protection
Protect eyes from exposure to arc. NEVER look at an
electric arc without protection.
Welding helmet or shield containing a filter plate shade
no. 12 ordenser must be used whenwelding. Place over
face before striking are.
Protect filter plate with a clear cover plate.
Cracked or broken helmet or shield should NOT be
worn; radiation can pass through to cause burns.
Cracked, broken, or loose filter plates must be replaced
IMMEDIATELY. Replace clear cover plate when broken,
pitted, or spattered.
Flash goggles with side shields MUST be worn under
the helmet to give some protection to the eyes should the
helmet not be lowered over the face before an arc is
struck. Looking at an arc momentarily with unprotected
eyes (particularly a high intensity gas-shielded arc) can
cause a retinal burn that may leave a permanent dark
area in the field of vision.
3. Protection of Nearby Personnel
Enclosed welding area. For production welding, a sepa-
rate room or enclosed bay is best. In open areas, sur-
round the operation with low-reflective, non-combusti-
ble screens or panels. Allow for free air circulation, par-
ticularly at floor level.
OM-481 Page 4
Viewing the weld. Provide face shields for all persons
who will be looking directly at the weld.
Others working in area. See that all persons are wearing
flash goggles.
Before starting to weld, make sure that screen flaps or
bay doors are closed.
B. Toxic Fume Prevention
Comply with precautions in 1-2B.
Generator engine exhaust must be vented to the outside
air. Carbon monoxide can kil.
C. Fire and Explosion Prevention
Comply with precautions in 1-2C.
Equipment's rated capacity. Do not overload arc welding
equipment. It may overheat cables and cause a fire.
Loose cable connections may overheat or flash and
cause a fire.
Never strike an arc on a cylinder or other pressure ves-
sel. It creates a brittle area that can cause a violent rup-
ture or lead to such a rupture under rough handling.
D. Compressed Gas Equipment
Comply with precautions in 1-2D.
E. Shock Prevention
Exposed hot conductors or other bare metal in the weld-
ing circuit, or in ungrounded, electrically-HOT equip-
ment can fatally shock a person whose body becomes a
conductor. DO NOT STAND, SIT, LIE, LEAN ON, OR
TOUCH a wet surface when welding, without suitable
protection.
To protect against shock:
Wear dry insulating gloves and body protection. Keep
body and clothing dry. Never work in damp area without
adequate insulation against electrical shock. Stay on a
dry duckboard, or rubber mat when dampness or sweat
can not be avoided. Sweat, sea water, or moisture be-
tween body and an electrically HOT part or grounded
metal reduces the electrical resistance, and could en-
able dangerous and possibly lethal currents to flow
through the body.
A voltage will exist between the electrode and any con-
ducting object in the work circuit. Examples of conduct-
ing objects include, but are not limited to, buildings, elec-
trical tools, work benches, welding power source cases,
workpieces, etc. Never touch the electrode and any
metal object unless the welding power source is off.
1. Grounding the Equipment
Arc welding equipment must be grounded according to
the National Electrical Code, and the work must be
grounded according to ANSI Z49.1 “Safety In Welding
And Cutting.”
When installing, connect the frames of each unit such as
welding power source, control, work table, and water cir-
culator to the building ground. Conductors must be ade-
quate to carry ground currents safely. Equipment made
electrically HOT by stray current may shock, possibly fa-
tally. Do NOT GROUND to electrical conduit, orto apipe
carrying ANY gas or flammable liquid such as oil or fuel.
Three-phase connection. Check phase requirements of
equipment before installing. If only 3-phase power is
available, connect single-phase equipment to only two
wires of the 3-phase line. Do NOT connect the equip-
ment ground iead to the third (live) wire, or the equip-
ment will become electrically HOT-a dangerous condi-
tion that can shock, possibly fatally.
Before welding, check ground for continuity. Be sure
conductors are touching bare metal of equipment
frames at connections.
If a line cord with a ground lead is provided with the
equipment for connection to a switchbox, connect the
ground lead to the grounded switchbox. If a three-prong
plug is added for connection to a grounded mating re-
ceptacle, the ground lead must be connected to the
ground prong oniy. If the line cord comes with a three-
prong plug, connect to a grounded mating receptacle.
Never remove the ground prong from a plug, or use a
plug with a broken off ground prong.
2. Electrode Holders
Fully insulated electrode holders should be used. Do
NOT use holders with protruding screws.
3. Connectors
Fully insulated lock-type connectors should be used to
join welding cable lengths.
4. (Cables
Frequently inspect cables for wear, cracks and damage.
IMMEDIATELY REPLACE those with excessively worn
or damaged insulation to avoid possibly-lethal shock
from bared cable. Cables with damaged areas may be
taped to give resistance equivalent to original cable.
Keep cable dry, free of oil and grease, and protected
from hot metal and sparks.
5. Terminals And Other Exposed Parts
Terminals and other exposed parts of electrical units
should have insulating covers secured before operation.
6. Electrode
a. Equipmentwith output on/off control (contactor)
Welding power sources for use with the gas
metal arc welding (GMAW), gas tungsten arc
welding (GTAW) and similar processes nor-
mally are equipped with devices that permit on-
off control of the welding power output. When so
equipped the electrode wire becomes electri-
cally HOT when the power source switch is ON
and the welding gun switch is closed. Never
touch the electrode wire or any conducting ob-
ject in contact with the electrode circuit unless
the welding power source is off.
b. Equipment without output on/off control (no
contactor)
Welding power sources used with shielded
metal arc welding (SMAW) and similar proc-
esses may not be equipped with welding power
output on-off control devices. With such equip-
ment the electrode is electrically HOT when the
power switch is tumed ON. Never touch the
electrode unless the welding power source is
off.
7. Safety Devices
Safety devices such as interlocks and circuit breakers
should not be disconnected or shunted out.
Before installation, inspection, or service, of equipment,
shut OFF all power and remove line fuses (or lock or red-
tag switches) to prevent accidental turning ON of power.
Disconnect all cables from welding power source, and
pull all 115 volts line-cord plugs.
Do not open power circuit or change polarity while weld-
ing. If, in an emergency, it must be disconnected, guard
against shock burns, or flash from switch arcing.
Leaving equipment unattended. Always shut OFF and
disconnect all power to equipment.
Power disconnect switch must be available near the
welding power source.
F. Protection For Wearers of Electronic Life Sup-
port Devices (Pacemakers)
Magnetic fields from high currents can affect pacemaker
operation. Persons wearing electronic life support
equipment (pacemaker) should consult with their doctor
before going near arc welding, gouging, or spot welding
operations.
1-4. STANDARDS BOOKLET INDEX
For more information, refer to the following standards or
their latest revisions and comply as applicable:
1. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126.
2. NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING obtainable
from the Superintendent of Documents, U.S. Gov-
ernment Printing Office, Washington, D.C. 20402.
3. OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable fromthe Superintendent of
Documents, U.S. Government Printing Office,
Washington, D.C. 20402.
4. ANSI Standard Z87.1, SAFE PRACTICES FOR
OCCUPATION AND EDUCATIONAL EYE AND
FACE PROTECTION obtainable fromthe American
National Standards Institute, 1430 Broadway, New
York, NY 10018.
5. ANSI Standard Z41.1, STANDARD FOR MEN'S
SAFETY-TOE FOOTWEAR obtainable from the
American National Standards Institute, 1430 Broad-
way, New York, NY 10018.
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES
OM-481 Page 5
obtainable from the American National Standards
Institute, 1430 Broadway, New York, NY 10018.
7. AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUS-
TIBLES obtainable from the American Welding So-
ciety, 550 N.W. LeJeune Rd, Miami, FL 33126.
8. NFPA Standard 51, OXYGEN-FUEL GAS SYS-
TEMS FOR WELDING, CUTTING, AND ALLIED
PROCESSES obtainable from the National Fire
Protection Association, Batterymarch Park, Quincy,
MA 02269.
NFPA Standard 70, NATIONAL ELECTRICAL
CODE obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA
02269.
10. NFPA Standard 518, CUTTING AND WELDING
PROCESSES obtainable from the National Fire
Protection Association, Batterymarch Park, Quincy,
MA 02269.
11. CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS obtainable
©
fromthe Compressed Gas Association, 1235 Jeffer-
son Davis Highway, Suite 501, Arlington, VA 22202.
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING obtainable fromthe Ca-
nadian Standards Association, Standards Sales,
178 Rexdale Boulevard, Rexdale, Ontario, Canada
MAW 1R3.
13. NWSA booklet, WELDING SAFETY BIBLIOGRA-
PHY obtainable from the National Welding Supply
Association, 1900 Arch Street, Philadelphia, PA
19103.
14. American Welding Society Standard AWSF4.1,
RECOMMENDED SAFE PRACTICES FOR THE
PREPARATION FOR WELDING AND CUTTING
OF CONTAINERS AND PIPING THAT HAVE HELD
HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd,
Miami, FL 33126.
15. ANSI Standard 288.2, PRACTICE FOR RESPIRA-
TORY PROTECTION, obtainable from the Ameri-
can National Standards Institute, 1430 Broadway,
New York, NY 10018.
SECTION 2 - SAFETY PRECAUTIONS AND SIGNAL WORDS
2-1. GENERAL INFORMATION AND SAFETY
A. General
Information presented in this manual and on various la-
bels, tags, and plates on the unit pertains to equipment
design, installation, operation, maintenance, and
troubleshooting which should be read, understood, and
followed forthe safe and effective use of this equipment.
The nameplate of this unit uses international symbols for
labeling the front pane! controls. The symbols also ap-
pear at the appropriate section in the text.
B. Safety
The installation, operation, maintenance, and trouble-
shooting of arc welding equipment requires practices
and procedures which ensure personal safety and the
safety of others. Therefore, this equipment is to be in-
stalled, operated, and maintained only by qualified per-
sons in accordance with this manual and all applicable
codes such as, but not limited to, those listed at the end
of Section 1 — Safety Rules For Operation Of Arc Weld-
ing Power Source.
OM-481 Page 6
2-2. SAFETY ALERT SYMBOL AND SIGNAL
WORDS
The following safety alert symbol and signal words are
used throughout this manualto call attention to and iden-
tity different levels of hazard and special instructions.
This safety alert symbol is used with the signal
words WARNING and CAUTION to call atten-
tion to the safety statements.
WARNING statements identify procedures or
practices which must be followed to avoid seri-
ous personal injury or loss of life.
practices which must be followed to avoid minor
4) CAUTION statements identify procedures or
personal injury or damage to this equipment.
IMPORTANT statements identify special instructions
necessary for the most efficient operation of this equip-
ment.
UVA оннНАОННОНВОПЬАОООЛЕН ОНО
SECTION 3 - SPECIFICATIONS
ZA
Table 3-1. Welding Generator Specifications
Maximum . : Weight
Rated Output DC/CC | DC/CV |. Maximum Singie-Phase 9
AL 100% | Welding | Ampere Open Circuit! Voltage Engine Speed | Auxiliary Power
Duty Cycle Range Ranges (OC ) Ranges ( o Load) While elding Net Ship
Min.-65 | 95 Volts DC 3 kVA/KW 60 Hz
mperes 55-120 2150 ibs. | 2280 №5.
AAA VOLS DE Amps DE 85-250 | 80 Volts DC | 14-36 1850 RPM 26. amps @ 120V | 197519) | (1034 kg)
[19-350 | Nominal 13 amps @ 240V
Conforms with NEMA EW1 (ANSI €87.1), "ELECTRIC ARC WELDING POWER SOURCES, " Class | (100).
21/32 in. (16.7 mm)
Diameter (All Holes)
|
H
G |
| F
E
D
|
SC 134 686
Base Mounting Hole Locations
A B Cc D E F G H | J K L
Inches 6-1/8 9-3/4 | 13-3/4 | 28-316 36 46-1/2 | 50-1/2 | 62-3/8 68 1-1/16 29-7/8 32
Millimeters | 155.6 | 247.7 | 349.3 716 914.4 | 1181.1 | 1282.7 | 1584.3 | 1727.2 27 758.8 | 812.8
Figure 3-1. Overall Dimensions And Mounting Hole Locations
OM-481 Page 7
ey
Chart 3-1. Volt-Ampere Curves
For Constant Current (CC) DC Mode
DC/CC WELD YOLTS
o 200 400 600 B00 ¡000 1200
SB-133 004
- Be,
For Constant Voltage (CV) DC Mode
DC/CV WELO VOLTG
s 8 # 8
58-133 003
3-1. VOLT-AMPERE CURVES (Chart 3-1)
(>> RATED OUTPUT
The volt-ampere curves show the voltage and amper-
age output capabilities of the welding generator. Curves
of other settings fall between the curves shown.
3-2. DUTY CYCLE (Chart 3-2)
The duty cycle of a welding generator is the percentage
of a ten minute period that a welding generator can be
operated at a given output without causing overheating
and damaging to the unit. This welding generator is
rated at 100 percent duty cycle when operated at 600
amperes. This means that the welding generator can be
operated at 600 amperes continuously without causing
damage to the unit.
OM-481 Page 8
Refer to the Duty Cycle Chart (Chart 3-2) io determine
the output of the welding generator at various duty
cycles.
CAUTION: EXCEEDING DUTY CYCLE RAT-
INGS will damage the welding generator.
® Do not exceed indicated duty cycles.
Chart 3-2. Duty Cycle
RATED OUTPUT —y
1200
1000
WELD AMPERES
40 50 60 70 80 80 100
% DUTY CYCLE
B-134 397-A
3-3. DESCRIPTION
This unitis a constant current/constant voltage (CC/CV)
de arc welding generator designed for use with the
Shielded Metal Arc Welding (SMAW), Gas Metal Arc
Welding (GMAW), Flux Cored Arc Welding (FCAW),
Submerged Arc (SAW), and Air Carbon Arc Cutting And
Gouging (AAC) processes.
The unit has a four-cylinder, air-cooled, Deutz diesel en-
gine (F4L-912).
In addition to welding capability, this unit can provide up
to 3 kVA/KW of 120/240 volts (26/13 amperes) ac electri-
cal power for operating 50/60 Hz or 60 Hz cord-con-
nected auxiliary equipment while welding.
This unitis specially prepared tor operation in harsh and
corrosive environments.
The following optional equipment can be provided onthe
welding generator and are covered within this Owner’s
Manual:
* Spark Arrestor
* Ether Starting Aid
* Locking Control Panel Cover
IMPORTANT: Fora complete listing of Options and Ac-
cessories, see back cover of this Owner's Manual.
EN _—_—_—_—_—_—_—_—_—_—_—_—_—_—_—_—_—_—_ _n_—_— —_—m— ——————————
SECTION 4 — INSTALLATION OR RELOCATION
IMPORTANT: Unless otherwise specified, all direc-
tions, such as left or right, are with respect to the opera-
tor facing the welding generator front panel.
4-1. LOCATION (Figure 3-1)
A properinstallation site should be selected forthe weld-
ing generator if the unit is to provide dependable service
and remain relatively maintenance free.
WARNING: ENGINE EXHAUST GASES can
Kill.
e Operate in open, well-ventilated areas or if
operated indoors, vent engine exhaust outside
the building.
e Keep engine exhaust vent outlet away from
building air intakes.
CAUTION: RESTRICTED AIRFLOW causes
overheating and possible damage to internal
parts.
® Maintain at least 18 inches (457 mm) of unre-
stricted space on all sides of unit, and keep
underside free of obstructions.
® Ро not place any filtering device over the
intake air passages of this welding generator.
Warranty is void if any type of filtering device is
used.
The service life and operating efficiency of this
unit are reduced when the unitis subjectedto ex-
treme levels of dust, dirt, moisture, corrosive va-
pors, and extreme heat.
>
A. Lifting Of Equipment
WARNING: INCORRECT LIFTING will dam-
age internal parts; FALLING EQUIPMENT
can cause serious personal injury and
equipment damage.
® Use lifting eye to lift unit only, NOT gas cylin-
ders, trailer, or any other heavy options, acces-
sories, or devices.
® [se equipment of adequate capacity to lift the
unit.
© Use lift forks at least 42 in. (1067 mm) long.
® Lift only from engine-end (end opposite front
panel.
B. Trailer Mounting
CAUTION: UNCONTROLLED TILTING OF
TRAILER can result in personal injury or
equipment damage.
® Distribute weight so that traiter tongue weight
Is approximately 10% of gross trailer weight.
© Follow trailer manufacturer's instructions
when mounting welding generator onto trailer.
OPERATION ON UNLEVEL SURFACE can
cause improper lubrication and result in
severe engine damage.
® Operate unit in an approximately level posi-
tion.
® See Figure 4-1 for maximum allowable tilt for
proper operation.
® Check crankcase oil level with unit on a level
surface.
Exceedingthese limits can cause severe engine
damage and improper operation.
Front
Panel
17.5 — a
15°
Side View Of Unit
End View Of Unit Ref. S-0024
Figure 4-1. Allowable Tilt Angles For Welding
Generator Engine
Holes are provided in the base for securing the unitin a
permanent location or to a trailer or transport vehicle.
Figure 3-1 gives overall dimensions and base mounting
hole layout.
The mounting location should allow sufficient roomto re-
move the top cover and side panels for maintenance and
repair functions.
Use a properly fitting cover (optional) over the welding
generator when not in operation to protect the unit from
the environment. Be sure unit is cool before installing
any Cover.
C. Spark Arrestor Considerations
WARNING: ENGINE EXHAUST SPARKS can
cause fire.
e Exhaust spark arrestor must be installed in
accordance with local, state, and federal regula-
tions.
The engine exhaust system onthis welding generatoris
not equipped with a spark arrestor. A spark arrestor,
maintained in effective working order, is mandatory if
this welding generator is to be operated in a National
OM-481 Page 9
Forest or on California Grasslands, brush, or forest cov-
ered land (see Section 4442 of California Public Re-
sources Code). Forother areas, check your state and io-
callaws. If a spark arrestor (optional) is desired, contact
your dealer/distributor.
4-2. EXHAUST EXTENSION INSTALLATION
WARNING: HOT ENGINE PARTS can cause
severe burns.
e [f applicable, shut down engine and allow ex-
haust system to cool before installing exhaust
extension.
—
+
Remove left, rear side panel.
2. Install exhaust extension through top cover open-
ing, over muffler extension elbow. (Be sure to face
weather cap away from air cleaner; see Figure 3-1.)
3. Secure exhaust extension to top cover of unit using
« supplied hardware.
4. Reinstall and secure left side panel.
4-3. CONNECTING THE BATTERY
WARNING: BATTERY ACID can burn eyes
and skin and destroy clothing and other ma-
terial.
e Wear a face shield and proper protective
clothing when working with batteries.
ABNORMAL VOLTAGE can cause damageto
engine electrical components.
® Do not operate engine without the battery
connected.
® Do notdisconnectthe battery while the engine
is running.
IMPORTANT: Be sure the Engine Control switch is in
the OFF position before connecting battery.
~ Thisunitis equipped with a maintenance-free battery. To
place the unitin service, remove the left, rear side panel,
connect the negative (-) battery cable to the negative
battery terminal, and reinstall the side panel. No other
preparation should be required. If the battery does not
supply enough power to crank the engine, charge the
battery according to Section 8-7.
4-4. FUEL
WARNING: ENGINE FUEL can cause fire or
explosion.
® Stop engine before checking or adding fuel,
® Do not spill fuel; if spilled, wipe up.
® Do not refuel if engine is hot or running.
® Do not refuel near sparks or open flame.
® Do not smoke while refueling.
® Do notfill fueltank to top; allow 1/2in. (13 mm)
from fuel to tank top for expansion.
OM-481 Page 10
IMPORTANT: Fillfueltankup to 1/2in. (13 mm)
from top with fresh fuel before starting engine
the first time. Rust and corrosion preventative
was added to inside of fuel tank and engine at
the factory and could cause rough engine run-
ning if not properly diluted with a full tank of fresh
fuel
e Do not weld on fuel tank.
The capacity of the fueltank is 19 gallons U.S. Measure
(73 liters). See the Engine Manufacturer's Manual for
fuel recommendations. Chart 4-1 illustrates typical fuel
consumption under specific load conditions. Fuel con-
sumption varies from one engine to another. Different
brands of fuel, operating conditions, condition of the en-
gine, etc., also affect the fuel consumption level.
Keep the fuel tank filled to ensure that the injector sys-
tem receives an adequate supply of fuel. The fuel capis
located onthe lower front panel, behind the access door
{see Figure 4-2). if the fuel tank is allowed to empty, air
will enter the system, causing starting problems. The
Engine Manufacturer's Manual outlines procedures for
air bleeding the fuel system,
Chart 4-1. Fuel Consumption Curve
3.78 0.55
2.54 0.52
9.95 0.31
200 50 400 500 500 00 800
DC WELD AMPERES AT 100X DUTY CYCLE
+] 100
SB-133 838
4-5. LUBRICATION
The engine is shipped with its crankcase filled with SAE
20 break-in oil. If the oil level is not up to the full mark on
the dipstick, add oil according to the recommendations
in the Engine Manufacturer's Manual (F4L.-812 Engine)
before starting the engine.
IMPORTANT: This engine is equipped with an Cil Pres-
sure Shutdown gauge/switch and an Oil Temperature
Shutdown gauge/switch. If oil pressure becomes too low
or oil temperature rises to a level that may cause engine
damage, the respective gauge/switch shuts down the
engine. The shutdown oil pressure has been factory set
at 30 psi (207 kPa), and the shutdown oil temperature
has been set at 250°F (121°C).
4-6. EQUIPMENT GROUNDING TERMINAL
À
GROUND
This unit is equipped with a grounding terminal for
grounding the generatorcase. The grounding terminalis
located on the right side of the lower front panel, behind
the access door {see Figure 4-2). Since the generator
neutral is connected to the frame, the equipment
grounding terminal must be connected to a proper earth
ground. Additionally, comply with all national, regional,
and local codes concerning portable generators for the
specific application.
For detailed grounding instructions consult your na-
tional, regional, and local codes. If additional information
regarding your operating circumstances and/or ground-
ing requirements is needed, consult a qualified electri-
cian or your dealer. After determining the extent to which
any grounding requirements apply to your particular
situation, foliow them explicitly.
4-7. WELD OUTPUT CONNECTIONS (Table 4-1 And
Figure 4-2)
RATED WELD OUTPUT
Ae
To obtain full rated output fromthis unit, itis necessary to
select, prepare, andinstall properweld cables. Failure to
complyin any of these areas may resultin unsatisfactory
welding performance.
A. Weld Cable Selection
Use the following guidelines to select weld cables:
1. Use the shortest possible cables, and place cables
close together. Excessive cable lengths may reduce
output or cause unit overioad due to added
resistance.
2. Use weld cable with an insulation voltage rating
equal to or greater than the maximum open-circuit
voltage (ocv) of the welding generator (see Table
3-1 for unit maximum ocv rating).
3. Select weld cable size according to maximum weld
output and total length of connecting cables in weld
circuit. For example, if a 25 foot (7.5 m) wire feeder
or electrode holder cable is used with a 25 foot (7.5
m) work cable, select the cable size recommended
in Table 4-1 for 50 feet (15 m).
4. Do not use damaged or frayed cables.
Table 4-1. Weld Cable Size
Total Cable (Copper) Length In Weld Circuit Not Exceeding*
Welding 100 fi. Or Less 150 fi. 200 ft. 250 ft. 300 ft. 350 ft. 400 ft.
Amperes (30 m) (45 m) (60 m) (70 m) (90 m) (105 m) (120 m)
10 To 60% ru 1009
Duty Cycle ty Cycle” 10 Thru 100% Duty Cycle
100 4 4 4 3 2 1 1/0 1/0
150 3 3 2 1 1/0 2/0 3/0 3/0
200 3 2 1 1/0 2/0 3/0 4/0 4/0
250 2 1 1/0 2/0 3/0 4/0 2-2/0 2-2/0
300 1 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0
350 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-3/0 2-4/0
400 1/0 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 2-4/0
500 2/0 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-3/0
600 3/0 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0
700 4/0 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 3-4/0 4-4/0
800 4/0 2-2/0 2-3/0 2-4/0 3-4/0 3-4/0 4-4/0 4-4/0
900 2-2/0 2-3/0 2-4/0 3-3/0 3-4/0 4-4/0 4-4/0
1000 2-2/0 2-3/0 2-4/0 3-3/0 4-3/0 4-4/0
1250 2-3/0 2-4/0 3-3/0 4-3/0 4-4/0
1500 2-4/0 3-3/0 3-4/0 4-4/0
"Weld cable size (AWG)
mils per ampere.
is based on either à 4 volts or less drop or a current density of more than 300 circ: iar
—-0007/8-88
OM-481 Page 11
B. Weld Cable Preparation
1. Install electrode holder to cable following manufac-
turer's instructions. Always use an insulated elec-
trode holder to ensure operator safety.
2. Install correct size lugs onto ends of both cables for
connecting to work clamp, electrode holder or wire
feeder, and weld output terminals.
3. Install work clamp onto cable.
C. Weld Output Connections
POSITIVE NEGATIVE
+ mou
WARNING: ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
® Stop engine, and disconnect negative (-) bat-
tery cable before making any weld output con-
nections.
MOVING PARTS can cause serious injury.
® Keep away from moving parts such as fans,
belts, and rotors.
== Ч
1. Open and secure the lower front panel access door,
and route weld cables through bracket on front up-
right to the weld output terminals (see Figure 4-2).
Route Strain
Weld Cables Relief
Through
This Bracket Remote 14
Receptacle
POSITIVE(+)
Weld Output
Terminals
NEGATIVE(-)
Weld Output Equipment
Terminals Grounding Terminal
Ref. SB-134 687
Figure 4-2. Weld Output Connections And
Lower Front Panei
OM-481 Page 12
2. For Shielded Metal Arc Welding (SMAW) and Air
Carbon Arc Cutting and Gouging (AAC) (Electrode
Positive/Reverse Polarity), connect weld cables as
follows:
a. Connectone endofworkcabieto NEGATIVE (-)
weld output terminal.
b. Connect end of electrode holder cable to POSI-
TIVE (+) weld output terminal.
IMPORTANT: For Electrode Negative/Straight Polarity
connections, reverse cable connections to weld output
terminals; electrode becomes negative.
3. ForWire Feeding Processes (GMAW, FCAW, SAW)
(Electrode Positive/Reverse Polarity), connect weld
cables as follows:
a. Connectone end of work cable to NEGATIVE (-)
weld output terminal.
b. Connect end of electrode holder cable to POSI-
TIVE (+) weld output terminal and remaining
end to terminal on the wire feeder drive housing
(see wire feeder Owner's Manual for location).
4. Close and secure front panel access door.
4-8. REMOTE CONTROL. CONNECTIONS
A. REMOTE 14 Receptacle Information And
Connections (Figures 4-2 And 4-4)
A/V AMPERAGE & VOLTAGE
OUTPUT
(CONTACTOR)
REMOTE 14 receptacle RC3, located under the lower
front panel access door (see Figure 4-2), is provided to
connect any of the following equipment to the welding
generator circuitry:
a. Remote Contactor
b. Remote Amperage or Voitage control
C. Wire feeder which provides contactor control to
the welding generator
d. Combination of the above.
To make connections, align keyway, insert plug, and ro-
tate threaded collar fully clockwise.
if the supplied remote control cord is not suitable for
connectingtothe REMOTE 14 receptacle RC3, proceed
with one of the following alternatives:
1. Wire a plug or cord to interface with REMOTE 14
receptacle RC3 using socket information in Section
C.
2. Wire remote control cord directly to terminal strip
within unit according to Section B.
B. Terminal Strip Information And Connections
(Figures 4-2, 4-3 And 4-5)
WARNING: ELECTRIC SHOCK can Kill; UN-
EXPRECTED OUTPUT can cause serious in-
jury. |
e Do not touch live electrical parts.
e Stop engine, and disconnect negative (-)
battery cable from battery before making any
internal inspection or connections.
e Do not connect to REMOTE 14 receptacle
and terminal strip at the same time.
Since the QUTPUT (CONTACTOR) can be
energized from eitherthe receptacle orterminal
strip, it is vital to use only one remote control
method.
MOVING PARTS can cause serious injury.
e Keep away from moving parts such as fans,
belts, and rotors.
Strain
Relief
Right Rear Side
Of Front Panel
Terminal
Label \ A 7
Terminal
Strip 3T
Front Right
Corner Of Base
Terminal Strip 3T
Information Label
5B-134 839
Figure 4-3. Terminal Strip Location
Terminal strip ST, mounted on the right rear side of the
front panel (see Figure 4-3), is included in case the plug
supplied on the remote control cord is not suitable for
connections to the REMOTE 14 receptacle RC3.
To make connections, proceed as follows:
1. Remove existing plug from remote control cord.
2. Openand secure lowerfront panel access door, and
remove right front side access panel.
3. Locate strain relief provided on lower front panel
(see Figures 4-2 And 4-3).
4. Insert leads from cord through strain relief.
5. Connect leads to terminal strip 3T using terminal
information provided in Section C.
6. Secure the cord in the strain relief.
7. Close and secure access door and right side panel.
C. Socket/Terminal Information (Figures 4-4 And
4-5)
The following lists the functions of the sockets of
REMOTE 14 receptacle RC3 (see Figure 4-4), and the
terminals of strip 3T(see Figure 4-5). Sockets and
terminals labeled with the same letter have identical
functions. For exampie, the function of socket A in
receptacle RC3 is identical to the function of terminal A
on strip 3T. The following sockeVierminal information is
provided in case it is necessary to wire the auxiliary
equipment cord.
No
5-0004
Figure 4-4. Front View Of REMOTE 14 Receptacie
With Socket Locations
Socket Terminal A:
Upto 10 amperes of 24 volt ac, 60 Hz, with respectto
socket G (circuit common); protected by circuit
breaker CB2.
Socket/Terminal B:
Input control to energize weld contactor for 24 volts
ac wire feeder. A contact closure from socket À to
socket B completes the 24 volt circuit.
Socket/Terminai C:
+10 volts dc with respect to socket D.
Socket/Terminal D:
Control circuit common for remote control device.
Socket/Terminal E:
Input command signal from wiper of remote control
potentiometer; O volts equals machine minimum;
+10 volts equals machine maximum.
Socket Terminal G:
24 and 115 volts ac circuit common; also connected
to welding power source chassis.
Socket Terminal |:
Upto 15 amperes of 115 volts ac, 60 Hz, with respect
to socket G (circuit common); protected by circuit
breaker CB1.
OM-481 Page 13
yc
- ie,
ST
24VAC 10A MAX
LS ANS
24VVAC Contactor Control
— © BO |
R
3
0-10VDC Reference ни
0-1 КО 2w VD CS
potentiometer
| Control Circuit Common
PCB
@ DO ——
0-10YDC Output Leve! Command
LS E® —
?
Circuit Common
f 1 e
| D | S | 115VAC 10AM
| S K D Equipment Ground
115VAC Contactor Control
e J®
Le ES |
|
|
External Device — | — Power Supply
S-133 149
— Figure 4-5. Terminal Strip Information
Socket Termina! J: cylinder is inserted. If dirt is present in either of these ar-
eas, the system may not work.
Input control to energize weld contactor for 115 volts у у
ac wire feeder. A contact closure from socket | to
socket J completes the 115 voit circuit.
1. Open and secure right rear side panel.
2. If applicable, remove protective cap from ether
Socket Termina! K: valve, or remove old ether cylinder from unit.
3. Loosen cylinder clamp, install ether cylinder, and
Machine chassis (circuit common). tighten clamp
IMPORTANT: The remaining sockets in the receptacle
are not used. IMPORTANT: After installing or replacing ether cylin-
der, do not use ortest ether start system for atleast 10 to
. 15 minutes to allow particles in fuel to settle to prevent
4-9. ETHER STARTING AID (Optional) | atomizer plugging.
This unit is shipped without the ether cylinder. Before
this device is operational, an ether cylinder must be ob-
tained and installed. To install the ether cylinder, pro-
ceed as follows:
WARNING: IMPROPER HANDLING OR EX-
POSURE TO ETHER can seriously harm your
ealth
e Follow the manufacturers safety instructions
on the cylinder when handling ether compo-
nents.
4. Using a liquid soap and water solution, check all
ether start system connections for leaks. If a leak ex-
ists, escaping gas will produce bubbles in the solu-
tion.
5. Close and secure side panel.
4-10. LOCKING CONTROL
(Optional)
This unit may be equipped with a clear polycarbonate
locking panel cover for use with a customer-supplied
padlock. The U-bolt used forsecuring the lock canbe ad-
PANEL COVER
IMPORTANT: Before installing the ether cylinder, clean
nozzle on ether cylinder and fitting into which the ether
OM-481 Page 14
justed for various padiocks. To make this adjustment
proceed as follows:
WARNING: ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
e Stop engine, and disconnect negative (-)
battery cable from battery before begin-
ning this installation.
MOVING PARTS can cause serious injury.
® Keep away from moving parts such as
fans, belts, and rotors.
HOT SURFACES can cause severe burns.
® Wear protective gloves and clothing when
working near a hot engine.
e Allow components to cool completely
before touching.
IMPORTANT: AJ directions, such as left or right, are
with respect to the operator facing the welding generator
front panel. Retain all hardware removed during this pro-
cedure for reinstallation unless specifically told
otherwise.
Remove the right front side access panel.
2. Loosen or tighten the hex nuts securing the U-bolt
on both the inside and outside of the cabinet.
3. Install side panel.
SECTION 5 —- AUXILIARY POWER
DT GO
POWER OUTPUT
WARNING: ELECTRIC SHOCK can kiil; MOV-
ING PARTS can cause serious injury; IM-
PROPER AIR FLOW AND EXPOSURE TO EN-
VIRONMENT can damage internal parts.
® Do not touch live electrical parts.
e Stop the engine and disconnect negative (-)
battery cable from battery before making inter-
nal inspection or reconnection.
® Ground generator as required by any applica-
ble national, state, and local electrical codes.
The generator neutrafis connected to the frame;
therefore, the equipment grounding terminal
must be connected to a proper earth ground.
® Do not connect to any electrical distribution
system normally supplied by utility power unless
a proper transfer switch and grounding proce-
dure are employed.
e Keep away from moving parts such as fans,
belts, and rotors.
® Keep all covers and panels in place while op-
erating.
Warranty is void if unit is operated with any por-
tion of the outer enclosure removed.
ELECTRIC SPARKS can cause fire.
® Disconnect weld cables when using auxiliary
power.
The weld output terminals are electricaily ener-
gized when the engine is running and the con-
tactor (if applicable) is energized.
e Watch for fire.
® Have a fire extinguisher nearby, and know
how to use it.
LOW VOLTAGE AND FREQUENCY can dam-
age electrical equipment.
e Turnoforunplug allelectrical equipmentcon-
nected to auxiliary power before starting or stop-
ping the engine.
When starting or stopping, the engine has low
speed which causes low voltage and frequency.
5-1. GENERAL
Calculate load requirements before connecting equip-
ment to the auxiliary power receptacles or junction box.
For best performance (voltage and frequency regula-
tion), limit connected load to approximately 90% of gen-
erator capability.
À brief period (less than 5 seconds) of large current draw
is required for starting motor-driven equipment. This —.
generator can suppiy 25% of rated current output at the
exciter power duplex receptacles for motor starting. For
best performance, use 240 volt motors. Disconnect mo-
tor from generator before starting engine. Use adequate
size cords so that voltage drop at the motoris not exces-
sive. Voltage drops significantly when starting motor-dri-
ven equipment.
Ground fault circuit interrupters (GFC!) may be required
for use with the duplex receptacles. Check local and
state codes, and the latest issue of the National Electri-
cal Code.
5-2. AUXILIARY POWER RECEPTACLES (Chart 5-1
And Figure 6-1)
A. General
This unitis equipped with duplex receptacles onthe low-
erfront panel (see Figure 6-1) for use with 50/60 Hzor 60
Hz cord-connected auxiliary equipment. The generator
is capable of providing a total of 3 KVA/KW of 60 Hz, sing-
le-phase, three-wire ac power while welding (see Chart
5-1).
OM-481 Page 15
IMPORTANT: The 3 kVA/kW is shared by all front panel
receptacles. The combined loading of all front panel re-
ceptacies cannot exceed 3 kVA/kW.
Chart 5-1. AC Power Curve For 120 And 240 Volts
Duplex Receptacies (No Weld Load Condition)
260 130
250 125
240 120
м
= 230 115
S
ee 220 110
Ш
S 210 105
O
&
O 200 100
<
190 95 E
£ 180 90
| | C4 4
0 10 20 30 40 50
AC POWER AMPERES AT 120V.
5 10 15 20 25
AC POWER AMPERES AT 240V.
B-109 365-A
B. 120 Volts AC Duplex Receptacle Specifications
120V26A /N AC
The 120V 26A AC duplex receptacie provides 120 volts
ac, 26 amperes of 60 Hz single-phase power for use
while welding. Each half of this receptacle can provide
15 amperes of 120 volts ac power, but total ioad cannot
exceed 26 amperes.
C. 240 Volts AC Duplex Receptacle Specifications
240V 13A NAC
The 240V 13A AC duplex receptacle provides 240 volts
ac, 13 amperes of 60 Hz single-phase power for use
while welding. Each half of this receptacle can provide
13 amperes of 240 volts ac power, but total load cannot
exceed 13 amperes.
D. Connections
The 120 and 240 volts ac duplex receptacles are for use
with cord-connected auxiliary equipment. Plugin or turn
on equipment when engine is running at weld/power
speed (1850 rpm).
E. Protection
The 3KVA/KW auxiliary power windings of the generator
are overload protected by design. However, the cus-
tomer must supply auxiliary equipment overioad protec-
tion if overload protection is required.
The 120 and 240V duplex receptacles are protected
from overload by circuit breakers CB1 and CB2 (see Fig-
ure 8-1). Whenever an overioad occurs and either CB1
or CB2 opens, both the 240V duplex receptacle and half
of the 120V duplex receptacle will not operate. See Sec-
tion 9-3 for circuit breaker resetting procedures.
SECTION 6 — OPERATOR CONTROLS
6-1. RANGE SWITCH (Figure 6-1)
A
AMPERE RANGES
DO NOT SWITCH UNDER LOAD
O:
The Range switch provides selection of coarse
amperage or voltage ranges for either constant current
(CC) or constant voltage (CV) operations.
A. Constant Current (CC) Positions
The Range switch provides selection of five coarse am-
perage ranges for constant current (CC) operations
(SMAW and AAC). The range of each switch position is
displayed on the nameplate.
OM-481 Page 16
when using the CC mode (see Section 6-4), place the
Range switch and the AMPERAGE & VOLTAGE AD-
JUSTMENT control (see Section 6-2) in the desired po-
sitions. If remote amperage control is used, the mini-
mum to maximum amperage range selection at the re-
mote control will be a percentage of the AMPERAGE &
VOLTAGE ADJUSTMENT control setting.
B. Constant Voltage (CY) Position
The Range switch provides selection of one coarse volt-
age range for constant voltage (CV) operations (GMAW,
FCAW, and SAW). The range of the switch position is
displayed on the nameplate.
When using the CV mode (see Section 6-4), place the
Range switch in the maximum position and use the AM-
PERAGE & VOLTAGE ADJUSTMENT control (see Sec-
tion 6-2) to select the desired voltage. If remote voltage
controtis used, the minimum to maximum voltage range
selection atthe remote contro! will be a percentage of the
AMPERAGE & VOLTAGE ADJUSTMENT control set-
ting.
CAUTION: ARCING can damage switch con-
tacts.
e Do not change the position of the Range
switch while welding or under load.
Arcing causes the contacts to become »itted and
eventually inoperative.
6-2. AMPERAGE & VOLTAGE ADJUSTMENT CON-
TROL (Figure 6-1)
A/V
AMPERAGE & VOLTAGE ADJUSTMENT
If the unit is inthe constant current (CC) mode (see Sec-
tion 6-4), the AMPERAGE & VOLTAGE ADJUSTMENT
Voltmeter Ammeter Amperage &
Voltage
control selects a welding amperage between the mini-
mum and maximum values of the coarse range selected
by the Range switch (see Section 6-1).
If the unit is in the constant voltage (CV) mode (see Sec-
tion 6-4), the AMPERAGE & VOLTAGE ADJUSTMENT
control selects an open-circuit voltage. When using CV,
the Range switch mustbe inthe maximum coarse range.
The scale surrounding the AMPERAGE & VOLTAGE
ADJUSTMENT controlis calibrated in percent and does
not indicate an actual amperage or voltage value.
IMPORTANT: The AMPERAGE & VOLTAGE ADJUST-
MENT control may be adjusted while welding.
Adjustment ¢ Ether Start
Controi
”
* A
À
ñ
À
Range Switch _ a
Switch
|
Service Engine
Air Cleaner
Indicator Light
Remote Amperage
& Voltage Control
Switch
CC/CV Switch
Output
(Contactor)
Switch
Check Cooling System/
Ba Alternator Indicator Light
AZ A ml
ye, O a |
= | Engine Control Switch
ee и » \
i,
Engine Hours Meter
Circuit Breakers —.% N F uel Gauge
CB1 And CB3 о
(see Section 9-3) « A Oil Temperature
| Ry a y Gauge/Switch
3 “6 ;
Ny 3 Qil Pressure
. $ Gauge/Switch
Q © бах
240V 13A А | Ñ
Duplex Receptacie 3
(see Section 5-2) Battery Ampere
Gauge
120V 26A AC
Duplex Receptacle
(see Section 5-2)
Remote 14
Recepiacie
(see Section 4-8) Equipment
Circuit Breakers
CB3 And CB4
(see Section 9-3)
* OPTIONAL Grounding Terminal
Ref. SB-134 687
Figure 6-1. Operator Controls
OM-481 Page 17
6-3. ENGINE CONTROL SWITCH (Figure 6-1)
OFF(®) €; run
START
The Engine Control switch has three positions: START,
RUN, and OFF.
A. START Position
START
Rotating the switch to the START position starts the en-
gine. Release the switch as soon as the engine starts,
and the switch automatically returns to the RUN posi-
tion.
B. RUN Position
És RUN
When the Engine Control switch is in the RUN position,
engine speed remains at governed weld/power speed
(1850 rpm).
OFF)
C. OFF Position
Rotating the Engine Control switch to the OFF position
disconnects battery voltage, thereby shutting down the
engine.
6-4. CONSTANT CURRENT/CONSTANT VOLTAGE
(CC/CV) SWITCH (Figure 6-1)
cc ff
il
of
me
The CC/CV switch provides a means of selecting weld
output characteristics for the desired process. The CV
(constant voltage) position causes the unit to provide a
constant voltage output specifically designed for wire
feeding applications (GMAW and FCAW). When using
the CV mode, place the Range switch in the maximum
position.
The CC (constant current) position causes the unit to
provide a constant current output specifically designed
for Shielded Metal Arc Welding (SMAW) and Air Carbon
Arc Cutting and Gouging (AAC).
OM-481 Page 18
6-5. REMOTE AMPERAGE & VOLTAGE CONTROL
SWITCH (Figure 6-1)
PANEL
7] REMOTE 14
AN
AMPERAGE & VOLTAGE
WARNING: ELECTRIC SHOCK can kill.
e Do not touch live electrical parts.
e Do not touch the output terminals when the
contactor is energized
® Do not touch welding wire or electrode and
work clamp at same time,
If remote amperage or voltage control is desired, make
connections to either the REMOTE 14 receptacle or the
terminal strip according to Section 4-8, and place the
AMPERAGE & VOLTAGE switch in the REMOTE posi-
tion. When a Remote Amperage or Voltage Control is
being used, the remote control functions as a fine am-
perage or voltage adjustment for the AMPERAGE &
VOLTAGE ADJUSTMENT control onthe welding gener-
ator. For example, if the AMPERAGE & VOLTAGE AD-
JUSTMENT control on the welding generator is set at
midrange, the Remote Amperage or Voltage Control will
provide (from minimum to maximum adjustment) fine
amperage or voltage adjustment of one half of the weld-
ing generator output for the range selected. For com-
plete remote control of the output, rotate the AMPER-
AGE & VOLTAGE ADJUSTMENT control to the maxi-
mum position.
If remote amperage or voltage is not desired, place the
AMPERAGE & VOLTAGE switchin the PANEL position.
Only the AMPERAGE & VOLTAGE ADJUSTMENT con-
trol will adjust output.
6-6. OUTPUT(CONTACTOR) SWITCH (Figure 6-1)
| ON
[7] ВЕМОТЕ 14
OUTPUT
(CONTACTOR)
WARNING: ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
® Do not touch the output terminals when the
contactor is energized.
® Do not touch welding wire or electrode and
work clamp at same time.
When the QUTPUT/CONTACTOR switch is in
the ON position, open-circuit voltage is present
atthe weldoutput terminais for as long as the en-
gine is running.
If the OUTPUT{CONTACTOR) switch is in the PANEL
position, open-circuit voitage will be present at the out-
put terminals whenever the engine is running.
If remote contactor control by means of a wire feeder or
remote device is desired, make connections to eitherthe
REMOTE 14 receptacle or the terminal strip according
to Section 4-8, and place the OUTPUT(CONTACTOR)
switch inthe REMOTE 14 position. Open-circuit voltage
is present at the weld output terminals wheneverthe gun
switch or remote device is closed.
6-7. SERVICE ENGINE AIR CLEANER INDICATOR
(Figure 6-1)
This unit is equipped with an engine air cleaner. When
the SERVICE ENGINE AIR CLEANER Indicator light
PL1 comes on, the air cleaner requires servicing (see
Section 8-2).
6-8. COOLING SYSTEM/ALTERNATOR INDICA-
TOR (Figure 6-1)
The CHECK COOLING SYSTEM/ALTERNATOR Indi-
cator light PL3 comes onif the engine cooling system or
alternator requires servicing. When the light comes on,
the engine shuts down. If the light comes on, check for
loose or broken engine belt according to Sections 8-5
and 8-10, respectively.
6-9. HOUR METER (Figure 6-1)
i
ENGINE HOURS
This unit is equipped with an hour meter. The meter, la-
beled ENGINE HOURS, registers the total hours of en-
gine operation. This information is useful for routine
maintenance on the engine.
6-10. FUEL GAUCE (Figure 6-1)
x
FUEL
The FUEL Gauge indicates the level of fuel remaining in
the fuel tank. The unitis equipped with a 19 gallon (73 L)
fuel tank.
6-11. LOW OIL PRESSURE/HIGH COOLANT TEM-
PERATURE SHUTDOWN SYSTEM SWITCH
Aninternal switch automatically shuts down the engine if
oil pressure drops to an unsafe level or coolant
temperature becomes too high.
The switch assembly is located directly behind the upper
front panel access door, in the upper right corner. The
switchs protected by a fuse located onthe bottom of the
switch assembly. Should this fuse open, the engine
would not start. See Section 9-3 for fuse replacement
procedure.
6-12. OIL TEMPERATURE GAUGE/SWITCH (Figure
6-1)
NA
AAS
OIL
TEMP
The Oil Temperature gauge/swiich (labeled OIL TEMP)
registers the temperature of the oitinthe lubricating sys-
tem. If the oil temperature rises to a level that may cause
engine damage (factory set at 250°F, 121°C), the engine
will automatically shut down. Normal oil operating tem-
perature is approximately 225°F (107°C).
6-13. OIL PRESSURE GAUGE/SWITCH (Figure 6-1)
OIL
PRESSURE
The OIL PRESSURE gauge/switch registers the lubri-
cating system pressure in pounds per square inch (psi).
The pressure registered by the gauge should remain
constant for a given engine speed. Should the pressure
fluctuate ordrop, stop the engine, and do not operate un-
tit the trouble has been corrected. If the oil pressure
drops to a level that may cause engine damage, the en-
gine will automatically shut down. The shut-down oil
pressure is factory set at 30 psi (207 kPa). Normal oper-
ating pressure is approximately 50 psi (345 kPa).
6-14. BATTERY AMPERE GAUGE (Figure 6-1)
ENGINE
BATTERY
The ENGINE BATTERY Ampere gauge registers the al-
ternator supplied output current to the battery. The
gauge should always register at 0 (zero) or a positive
number while the engine is running. If the gauge regis-
ters at a negative number, indicating that the battery is
discharging, stop the engine, and determine the cause.
Do not operate the engine until the trouble has been cor-
rected.
6-15. METERS (Figure 6-1)
The meters are provided to monitor the welding opera-
tion; however, they are not intended for exact amperage
or voltage measurements. These meters are internaily
connected to the output circuit.
The voltmeter indicates the voltage at the weld termi-
nals, but not necessarily the actual voltage at the weid-
ing arc {due to cable resistance, poor connections, etc.).
The ammeter indicates the amperage output of the unit.
OM-481 Page 19
—
6-16. ETHER STARTING AID (Optional) (Figure 6-1)
The cold weather starting components provide a means
of applying a premeasured portion of ether into the man-
ifold. The amount of ether supplied should be sufficient
to permit easy engine starting under cold weather condi-
tions.
Actuating the ETHER STARTING AID switch for one
second while cranking the engine will provide the proper
amount of ether to the manifold. This control will function
only while cranking the engine.
GINE IS RUNNING can cause engine dam-
age.
® Do not actuate ETHER STARTING AID while
engine is running.
&\ CAUTION: ETHER INJECTION WHILE EN-
IMPORTANT: The measured quantity of ether is
sprayed into the engine when this switch is released. Ac-
tuating the switch does not spray the ether into the en-
gine but rather fills the valve chamber.
SECTION 7 — SEQUENCE OF OPERATION
WARNING: ELECTRIC SHOCK can Kill;
MOVING PARTS can cause serious injury;
IMPROPER AIR FLOW AND EXPOSURE TO
ENVIRONMENT can damage internal parts.
e Do not touch live electrical parts.
e Stop the engine and disconnect negative (-)
battery cable from battery before inspecting or
servicing.
e Keep away from moving parts such as fans,
belts, and rotors.
e Keep all covers and panels in place while op-
erating.
Warranty is void if the welding generatoris oper-
ated with any portion of the outer enclosure re-
moved.
ARC RAYS can burn eyes and skin; NOISE
can damage hearing.
- Ea,
e Wear correct eye, ear, and body protection.
FUMES AND GASES can seriously harm
your health.
e Ventilate to keep from breathing fumes and
gases.
© /f ventilation is inadequate, use approved
breathing device.
® (Jse in open, well ventilated areas or vent ex-
haust out of doors.
HOT METAL, SPATTER, SLAG, and EX-
HAUST can cause fire and burns.
e Watch for fire.
® Have a fire extinguisher nearby, and know
how to use tt.
® Allow work and equipment to cool before han-
dling.
ENGINE FUEL can cause fire or explosion.
e Stop engine before checking or adding fuel.
® Do not spill fuel; if spilled, wipe up.
® Do not refuel if engine is hot or running.
® Do not refuel near sparks or open flame.
® Do not smoke while refueling.
e
Do not fill tank to top; allow room for expan-
sion.
OM-481 Page 20
MAGNETIC FIELDS FROM HIGH CURRENTS
can affect pacemaker operation.
e Wearers should consult with their doctor be-
fore going near arc welding, gouging, or spot
welding operations.
See Section 1-Safety Rules For Operation Of
Arc Welding Power Source for basic welding
safety information.
7-1. SHIELDED METAL ARC WELDING (SMAW)
WARNING: Read and follow safety informa-
tion at beginning of entire Sections 5 and 7
before proceeding.
Install and connect unit according to Section 4.
2. Wear dry insulating gloves and clothing.
3. Connect work clamp to clean, bare metal at
workpiece.
4. Select proper electrode.
5. Place the CC/CV switch in the CC position.
6. Rotate the Range switch and AMPERAGE & VOLT-
ÂGE ADJUSTMENT controltothe desired positions
(see Sections 6-1 and 6-2).
7. if remote amperage control is not used, place the
AMPERAGE & VOLTAGE switch in the PANEL po-
sition. If remote amperage control is to be used,
place the AMPERAGE & VOLTAGE switch in the
REMOTE position.
IMPORTANT: Electrode Positive/Reverse Polarity
should be used for most Shielded Metal Arc Welding
(SMAW) applications.
8. If remote contactor control is not used, place the
QUTPUT(CONTACTOR) switch in the ON position.
If remote contactor control is to be used, place the
QUTPUT{CONTACTOR) switch inthe REMOTE 14
position.
9. Start the engine as instructed in Section 7-6.
10. Connect desired auxiliary equipment to the 120V
26A and 240V 13A ac duplex receptacles (see
Section 5-2).
11. Placethe Engine Control switch inthe RUN position.
12. Energize auxiliary equipment, if applicable.
13. Wear welding helmet with proper filter lens accord-
ing to ANSI Z49.1.
14. Insert electrode into electrode holder.
15. Begin welding.
7-2. GAS METAL ARC (GMAW) AND FLUX CORED
ARC WELDING (FCAW)
WARNING: Read and follow safety informa-
tion at beginning of entire Sections 5 and 7
before proceeding.
Install and connect unit according to Section 4.
2. Install and connect wire feeder to the REMOTE 14
receptacle or terminal strip according to wire feed
equipment Owner's Manual and Section 4-8.
3. If shielding gas is required, make ail the necessary
connections.
4. Placethe CC/CV switchinthe proper position as de-
termined by the selected welding process (see Sec-
tion 6-4).
IMPORTANT: Constant voltage (CV) output should be
used for most Gas Metal Arc Welding (GMAW) and Flux
Cored Arc Welding (FCAW) applications.
5. Place the Range switch in the 190-MAX position,
and rotate the AMPERAGE & VOLTAGE ADJUST-
MENT contro! to the desired position (see Sections
6-1 and 6-2).
IMPORTANT: When using the CY mode, place the
Range switch on the welding generator in the maximum
position, and use the AMPERAGE 8 VOLTAGE AD-
JUSTMENT control to select the desired voltage. If re-
mote voltage control is used, the minimum to maximum
voltage range selection at the remote control will be a
percentage of the AMPERAGE & VOLTAGE ADJUST-
MENT control setting (see Section 6-2).
When using the CC mode, place the Range switch and
the AMPERAGE & VOLTAGE ADJUSTMENT control on
the welding generator in the desired positions. If remote
amperage control is used, the minimum to maximum
amperage range selection at the remote control will be a
percentage of the AMPERAGE & VOLTAGE ADJUST-
MENT control setting (see Section 6-2).
IMPORTANT: Electrode Positive/Reverse Polarity is
used for most Gas Metal Arc Welding (GMAW) applica-
tions. Flux Cored Arc Welding (FCAW) applications may
use either Electrode Positive/Reverse Polarity or Elec-
trode Negative/Straight Polarity, depending upon the
welding wire manufacturer's specifications.
6. If remote amperage or voltage control is not used,
place the AMPERAGE & VOLTAGE switch in the
PANEL position. If remote amperage or voltage con-
trol is to be used, place the AMPERAGE & VOLT-
AGE switch in the REMOTE 14 position.
7. If remote contactor control is not used, place the
QUTPUT(CONTACTOR) switch inthe ON position.
If remote contactor control is to be used, place the
QUTPUT(CONTACTOR) switch inthe REMOTE 14
position.
8. Wear dry insulating gloves and clothing, and wear
welding helmet with proper fitter lens according to
ANSI 248.1.
9. Prepare for welding as follows:
a. Connect work clamp io clean, bare metal at
workpiece.
b. Select and obtain proper welding wire, and
thread as instructed in wire feeder Owner's
Manual.
10. Turn on shielding gas at the source, if applicable.
11. Start the engine as instructed in Section 7-6.
12. Place the Engine Control switchinthe RUN position.
13. Connect desired auxiliary equipment to the 120V
26A and 240V 13A AC duplex receptacles {see Sec-
tion 5-2).
14. Energize the auxiliary equipment, if applicable.
15. After the engine has warmed up to operating tem-
perature, begin welding.
7-3. SUBMERGED ARC WELDING (SAW)
WARNING: Read and follow safety informa-
tion at beginning of entire Sections Sand 7
before proceeding.
1. Install and connect unit according to Section 4.
2. Install and connect wire feeder to the REMOTE 14
receptacle or terminal strip according to wire feed
equipment Owners Manual and Section 4-8.
3. Install flux system according to its Owner’s Manual.
4. Place the CC/CV switch in the CV position.
5. Place the Range switch in the 190-MAX position,
and rotate the AMPERAGE & VOLTAGE ADJUST-
MENT control to the desired position (see Sections
6-1 and 6-2).
6. lf remote contactor control is not used, place the
QUTPUT(CONTACTOR) switch in the ON position.
if remote contactor control is to be used, place the
OUTPUT(CONTACTOR) switch inthe REMOTE 14
position.
7. lf remote amperage or voltage control is not used,
place the AMPERAGE & VOLTAGE switch in the
PANEL position. If remote amperage or voltage con-
trol is to be used, place the AMPERAGE & VOLT-
AGE switch in the REMOTE 14 position.
8. Wear dry insulating gloves and clothing, and wear
safety goggles with correct filter shade according to
ANSI Z48.1.
OM-481 Page 21
=
8. Prepare for welding as follows:
a. Connect work clamp to clean, bare metal at
workpiece.
b. Select and obtain proper welding wire, and
thread as instructed in wire feeder Owner's
Manual.
с. Select and obtain proper flux, and put into flux
system.
10. Start the engine as instructed in Section 7-6.
11. Placethe Engine Control switchinthe RUN position.
12. Connect desired auxiliary equipment to the 120V
26A and 240V 13A AC duplex receptacles (see Sec-
tion 5-2).
13. Energize the auxiliary equipment, if applicable.
14. Make adjustments to wire feeder.
15. Turn on flux system.
16. After the engine has warmed up to operating tem-
perature, begin welding.
Table 7-1. Suggested Electrode Diameter For
Amperage Range (AAC Only)
Electrode Diameter Amperage Range
inches | Millimeters | Minimum | Maximum
1/8 3.2 30 — 60
5/32 4.0 90 150
3/16 4.8 200 250
1/4 6.4 300 400
5/16 7.3 350 450
3/8 9.5 450 600
1/2 12.7 800 1000
5/8 15.9 1000 1250
3/4 19.0 1250 1600
1 25.4 1600 2200
7-4. AIR CARBON ARC CUTTING AND GOUGING
(AAC) (Table 7-1)
WARNING: Read and follow safety informa-
tion at beginning of entire Sections 5 and 7
before proceeding.
install and connect unit according to Section 4.
Connect compressed air supply.
Place the CC/CV switch in the CC mode.
Place the AMPERAGE & VOLTAGE switch in the
PANEL position.
5. Place the OUTPUT(CONTACTOR) switch in the
ON position.
1.
2.
3.
4.
OM-481 Page 22
IMPORTANT. Electrode Positive/Reverse Polarity is
used for most Air Carbon Arc Cutting and Gouging
(AAC) applications.
6. Rotate the Range switch and AMPERAGE & VOLT-
AGE ADJUSTMENT control to the desired positions
(see Table 7-1).
7. Wear dry insulating gloves and clothing, and wear
welding helmet with proper filter lens according to
ANSI 249.1.
8. Prepare for cutting or gouging as follows:
a. Connect work clamp to clean, bare metal at
workpiece.
b. Select and obtain proper carbon electrode, and
insert into torch.
9. Turn on air supply.
10. Start the engine as instructed in Section 7-6.
11. Placethe Engine Control switch in the RUN position.
12. Connect desired auxiliary equipment to the 120V
26A and 240V 13A AC duplex receptacles (see
Section 5-2).
13. Energize the auxiliary equipment, if applicable.
14. After the engine has warmed up to operating tem-
perature, begin cutting or gouging.
7-5. AUXILIARY POWER OPERATION
WARNING: Read and follow safety informa-
tion at beginning of entire Sections 5 and 7
before proceeding.
1. install and connect unit according to Section 4.
2. Read entire Section 5 for auxiliary power operation
information.
3. Star the engine as instructed in Section 7-6.
Place the Engine Control switch inthe RUN position.
5. Connect desired auxiliary equipment to the 120V
26A and 240V 13A AC duplex receptacles (see Sec-
tion 5-2).
6. Energize the auxiliary equipment, if applicable.
Power may be obtained fromthe duplex receptacles
whenever the engine is running.
7-6. STARTING THE ENGINE
IMPORTANT: Read entire engine Owner's Manual
(Deutz F4L-912 engine) before operating engine.
1. Engine Prestart Checks
a. Check engine oil level. if oil level is low, fill to top
mark on dipstick (see Engine Manufacturer's
Manual for selection specifications).
b. Fuel Level
Check fuel level. If necessary, fil tank with fresh,
clean fuel (see Engine Manufacturer's Manual
for fuei specifications).
c. Cooling System
Check the air cooling system by inspecting the
air intake and exhaust openings for blockage
and blower impeller for obstruction and free
movement. Check the blower/alternator belt for
proper tension (see the Engine Manufacturer's
Manual), and ensure that all sheet metal cowl-
ings, shrouds, and panels are properly in place
and secure.
Rotate the Engine Control switch tothe START posi-
tion, and if applicable, depress the ETHER START-
ING AID switch, if applicable, at the same time —re-
lease ETHER STARTING AID switch after one sec-
ond.
no
CAUTION: REENGAGING STARTER MO-
TOR while flywheel is rotating or EXCEED-
ING RATED CRANKING TIME can damage
starting components.
® Do not reengage starter motor until starter
pinion and flywheel have stopped rotating.
® Do not exceed maximum cranking time of 20
seconds.
Allow two minutes cooling time before attempt-
ing to restart engine.
3. As soon as the engine starts, release the Engine
Control switch, and allow the engine to warm up for
approximately three minutes with no weld or power
load applied.
7-7. STOPPING THE ENGINE
1. Stop all operations, and turn off or disconnect any
auxiliary equipment.
WARNING: HIGH CONCENTRATION OF
SHIELDING GAS can harm health or Kill.
e Shut off gas supply when not in use.
2. Allow the engine to run for a few minutes to permit
the internal engine temperatures to equalize. In-
crease the time if the engine has been operating for
an extended period or at full load.
3. Rotate the Engine Control switch to the OFF posi-
tion.
SECTION 8 — MAINTENANCE
8-1. ROUTINE MAINTENANCE (Table 8-1)
IMPORTANT: Every six months inspect the labeis on
this unit for legibility. All precautionary labels must be
maintained in a clearly readable state and replaced
when necessary. See the Parts List for part numbers of
precautionary labels.
WARNING: ELECTRIC SHOCK can kill.
® Оо not touch live electrical parts.
® Stop engine, and disconnect negative (-)
battery cable from battery before inspecting,
maintaining, or servicing.
MOVING PARTS can cause serious Injury.
® Keep away from moving parts such as fans,
belts, and rotors.
HOT ENGINE PARTS can cause severe
burns.
® Wear protective gloves and clothing when
Working on a hot engine.
BATTERY ACID can burn eyes, skin, destroy
clothing, and damage other material.
e Wear correct eye and body protection.
Maintenance to be performed only by qualified
persons.
A. Cables And Wiring
WARNING: Read and follow safety informa-
tion at beginning of entire Section 8-1 before
proceeding.
Check interconnecting wiring and connections for
tightness and flaws. Be sure that the weld output cable
connections are clean andtight. Check the insulation for
breaks or other signs of damage. Repair or replace
cables or wiring as necessary.
B. Battery
WARNING: Read and follow safety informa-
tion at beginning of entire Section 8-1 before
proceeding.
Inspect the battery for loose connections, damaged
cables, corrosion, cracked case or cover, loose
holddowns, and loose or deformed terminal posts.
Clean and tighten connections, replace cables, or
replace battery if necessary.
C. Oil, Filter, And Drain
WARNING: Read and follow safety informa-
tion at beginning of entire Section 8-1 before
proceeding.
The engine is equipped with a full-flow oii filter. Change
the oil and filter according to instructions on unit mainte-
nance label and in engine Owners Manual (Deutz
OM-481 Page 23
“=
Table 8-1. Maintenance Schedule
Frequency"
Maintenance
Every day.
Check fuel and oil levels (see Sections 4-4 and 8-1C, and engine Owner's
Manual, Deutz F4L-912 engine).
Every 40 hours.
Clean spark arrestor carbon trap, if applicable (see Section 8-13).
Every 100 to 150 hours.
Change oil and filter (see engine Owner's Manual, Deutz F4L-912 engine).
Check cables, wiring (see Section 8-1A), and battery (see Section 8-18).
(see Section 8-1).
Units in heavy service environments: Check labels; ciean and inspect unit
Change fuel/water separator (see Section 8-3).
Every 250 hours.
Inspect and service spark arrestor (see Section 8-13.)
Every 1000 hours.
Section 8-1D).
Replace fuel filter (see Section 8-4).Check brushes and slip rings {see Section 8-11).
Check all labels (see IMPORTANT block, Section 8-1). Clean and inspect unit (see
"Frequency of service is based on unit operated 40 hours per week. Increase frequency of maintenance if usage
exceeds 40 hours per week.
F4L-912 engine). Use correct type and grade of oil as
listed ininstructions for expected temperature range be-
fore next oil and filter change.
This unitis equipped with a side oil drain heldin a conduit
clamp inside the right base rail. Remove the plugto drain
oil from the engine.
IMPORTANT: This engine is equipped with an Oil Pres-
sure Shutdown gauge/switch and an Oil Temperature
Shutdown gauge/switch. If oil pressure becomes foo low
or oil temperature rises fo a level that may cause engine
damage, the respective gauge/switch shuts down the
unit. The shutdown oil pressure has been factory set at
30 psi (207 kPa), and the shutdown oil temperature has
been set at 250” F (121° C).
D. Cleaning And Inspecting
WARNING: Read and follow safety informa-
tion at beginning of entire Section 8-1 before
proceeding.
When performing routine oil changes at intervals
specified on the unit maintenance label, clean and
inspect the unit as follows:
1. Keep the inside of the welding generator clean by
blowing out the unit with clean, dry compressed air.
2. Wipe oil and fuel spills from engine immediately to
avoid accumulation of dust.
3. Check for fluid leaks indicating loose oil or fuel
connections. Tighten loose connections, and clean
oil or fuel spills off engine.
OM-481 Page 24
IMPORTANT: See the engine Owner's Manual (Deutz
F4L-912 engine) for complete engine care.
8-2. AIR CLEANER SERVICE (Table 8-2)
ÁL CAUTION: DIRTY AIR can damage engine.
® Do not operate engine with dirty air cleaner
element in place.
© [Do not operate engine without air cleaner ele-
ment in place.
The air cleaner is one of the most important parts of the
engine fromthe standpoint of engine life. If dirty air gets
into the engine, it can cause major engine damage within
a few operating hours. The air cleaner must be serviced
when the SERVICE ENGINE AIR CLEANER Indicator
light PL1 comes on. If PL1 comes on, empty dust cap,
and inspect air cleaner and element.
The air cleaner onthis unitis equipped with precleaners.
Remove the precleaner cover and empty the dust recep-
tacle when dirt accumulates up to the indicator marks on
the side of the precleaner.
IMPORTANT: À dirty air cleaner element is usually ac-
companied by a loss of power and excessive smoke in
the engine exhaust.
When it becomes necessary to service the air cleanerin
the field, follow the steps in Table 8-2. Keep a spare ele-
ment on hand for replacement. New elements are avail-
able from your welding equipment distributor.
Table 8-2. Air Cleaner Service
1. Stop engine.
5. Wipe out element chamber
7. Reinstall element.
Follow with clean, damp cloth.
These 2. Wipe off cover before 8. Replace cover.
opening air cleaner. 6. Inspect new element and all
Easy gaskets for shipping damage before use.
Steps: 3. Remove cover.
4. Remove element.
1. Don't attempt to service air 3. Don't leave open air cleaner exposed 5. For Donaclone air cleaners ,
cleaner with engine running. to blowing dust while you clean element. don’t blow out penacione tube
Heplace cover. section without element, cover
Important 2. Don't blow out the inside of and inner cover (if any)
the air cleaner with compressed 4. If air cleaner is horizontally mounted, correctly installed or you will
air. be sure that dust cup is positioned so blow dust into the engine.
arrows point up.
How To Clean element by one of the re-use. However, washing does (When cleaning Cyciopac
following methods: a better job and must be used when elements, do not remove
Clean exhaust soot has lodged in fine pores plastic fin assembly — back-
Elements Compressed Air or Washing. of the filter media. Use Donaldson D-1400 flowing with compressed air or
For detergent which contains a special washing will remove dust from
Compressed air is recommended 1additive for removing soot and carbon. beneath the fin assembly).
Re-Use when element will be re-used
immediately because a washed
element must be dried before
Compressed Air
Direct air through element in
the direction opposite to normal
air flow through the element.
Move nozzle up and down while
rotating element. Keep nozzle
at least one inch from pleated
paper. Maximum air pressure —
100 P.S.L
Replace element after 6 cleanings or
annually, whichever occurs first.
Washing
1. Soak element 15 minutes or more
in Donaldson D-1400 and water solution.
See carton for full instructions.
2. Rinse until water is clear (Maximum
water pressure 40 P.S.[.)
3. Air-dry or use warm flowing air, max.
160 F. Do not use compressed air or
light bulbs.
Inspection
Place bright light inside
element and rotate element
slowly. if any rupture, holies
or damaged gaskets are
discovered — replace.
S-0091:4-89
OM-48t Page 25
ey
8-3. FUEL/WATER SEPARATOR AND SLUDGE
DRAIN PLUG
WARNING: ENGINE FUEL can cause fire or
explosion.
® [Do not drain fueltank while engine is running.
® Do not smoke while handling fuel.
® Do not allow fuel to drain onto the engine or
other components.
® Do not spill fuel; if spilled, wipe up.
® Have a fire extinguisher nearby, and know
how to use it.
A. Fuel/Water Separator
The fuel/water separator, located on the right base rail
near the engine, is provided to drain off water from the
fuel system. Before starting the engine for the first time
each day, open the fuel drain plug on the bottom of the
separator, and drain the water into a metal container.
Close the drain plug at the first signs of fuel. The fuel/
water separator should be changed every 125 hours of
operation or every four months, whichever occurs first.
B. Sludge Drain Plug
A sludge drain plug, located on the lower right front cor-
ner of the unit, is provided to drain off sediment from the
fuel tank. Once a week, drain the sludge into a metal
container. lí the fuel is extremely dirty, drain the sludge
daily.
Fuel Filter
Engine Speed
Adjustment
Screw
8-4. FUEL FILTER (Figure 8-1)
WARNING: ENGINE FUEL can cause fire or
explosion.
® Stop engine before working on fuel system.
® Do not spill fuel; if spilled wipe up.
® Do not service fuel filter if engine is hot or run-
ning.
® Do not service fuel filter near sparks or open
flame.
® Do not smoke while servicing fuel filter.
® Have a fire extinguisher nearby, and know
how to use it.
This welding generator is equipped with a cartridge-type
fuel filterlocated above the oilfilteron the right side ofthe
unit. The fuel filter should be replaced after 1000 hours
of operation, or more often depending on the quality of
fuel used and how dusty and dirty the location is in which
the engine is being used. To replace the fuel filter, referto
the Engine Manufacturer's Manual.
8-5. CHECKING ENGINE BELT (Figure 8-1)
This unitis equipped with a single V-belt which drives the
engine cooling fan and the alternator. To check the en-
gine belt, proceed as follows:
IMPORTANT. The belt MUST BE checked for tightness
after the first 20 hours of operation.
Engine Coolant
Fan Pulley
Alternator
Adjustment Bracket
Alternator
Pulley
Alternator
Pivot Bolt
Engine
Belt
TC-134 730
Figure 8-1. Right Side And Rear View Of Unit
OM-481 Page 26
WARNING: ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
® Stop engine, and disconnect negative (-) bat-
tery cable before inspecting, maintaining, or
servicing.
MOVING PARTS can cause serious injury.
® Keep away from moving parts such as fans,
belts, and rotors.
HOT ENGINE PARTS can cause severe
burns.
® Wear protective gloves and clothing when
working on a hot engine.
IMPORTANT: For the following procedure, all direc-
tions, such as clockwise and counterclockwise, are with
respect to the operator facing the rear of the welding
generator.
1. Remove rear panel.
2. Remove guard from engine pulley.
3. Place a straight edge from the top of the engine pul-
ley to the top of the alternator pulley.
4. Pull the engine belt down away from the straight
edge as far as it will go, and measure the distance
from the belt to the straight edge. The belt must not
exceed a distance of 1/2 in. (12.7 mm) from the
straight edge. if the distance is greater than 1/2 in.,
adjust the belt as follows:
a. Loosen hex nut on alternator adjustment
bracket.
b. Loosen hex nut on alternator pivot bolt, located
on underside of alternator.
Pivot alternator clockwise until belt is tight.
d. Tighten hex nut on alternator pivot boit and al-
ternator adjustment bracket.
5. Check the belt for tightness as instructed at begin-
ning of Step 4. If necessary, repeat Steps 4a thru d.
6. Reinstall guard onto engine pulley.
7. Reinstall rear pane! onto unit.
8-6. BATTERY REPLACEMENT PROCEDURE
WARNING: SPARKS OR FLAMES can cause
BATTERY GASES to explode; BATTERY
ACID can burn eyes and skin.
® Stop engine before disconnecting or
connecting battery cables.
® Keep sparks, flames, cigarettes, and other
ignition sources away from batteries.
® Do not allow fools to cause sparks when
working on a battery.
® Always wear a face shield and proper
protective gloves and clothing when working on
a battery.
Use the following procedure to prevent sparks when
removing or installing a battery:
1. Be sure engine is fully stopped, and Engine Control
switch is in the OFF position.
Locate battery in unit.
3. Open door or remove panels as necessary.
Disconnect negative (-) battery cable first and
positive (+) cable last.
Remove holddown device.
Remove battery.
Install new (or charged) battery.
Reinstal! and secure holddown device.
© © чо oO
Connect positive (+) cable first and negative (-)
cable last.
10. Securely reinstall or close doors or panels.
8-7. MAINTENANCE-FREE BATTERY CHARGING
WARNING: CHARGING AFROZEN BATTERY
can cause the battery to explode and result
in serious personal injury or damage to
equipment.
e Allow battery to warm up to 60° F (16°C) be-
fore charging If battery is frozen.
BATTERY ACID can burn eyes and skin and
destroy clothing and other materials; BAT-
TERY GASES can explode and shatter bat-
tery.
® Wear a face shield, proper protective clothing,
and remove all metal jewelry.
® Do not spill or splash battery fluid.
® Do not apply pressure to walls of filled bat-
tery—use battery carrier or place hands on op-
posite corners when lifting battery.
® Keep sparks, flames, cigarettes, and other ig-
nition sources away from batteries.
® Use enough ventilation to keep battery gases
from building up during and for several hours af-
ter battery charging.
® Do not touch or move connections on battery
while baîtery charger is on.
® Turn battery charger off before making con-
nections to battery.
® Do not lean over battery when charging.
® Be sure battery charger connections to bat-
tery are clean and tight.
e Keep vent caps in place and cover top of bat-
tery with damp cloth.
® Be sure battery charger output matches bat-
tery voltage.
9 Turn the battery charger off before discon-
necting the charger from the battery.
OM-481 Page 27
f
r
1. Remove battery fromunit, and place on a level work-
table or other suitable surface.
2. ifbattery has removable vent caps, checkthe condi-
tion of the electrolyte as follows:
d. Check electrolyte temperature in one of the
center cells with a battery thermometer. For
each 10°F (6°C) increment above 80°F (27°C),
a correction factor of 0.004 specific gravity must
be added to the specific gravity reading takenin
Step 2b. For each 10°F (6°C) increment below
80°F (27°C), 0.004 must be subtracted fromthe
reading taken in Step 2b.
b. Check the specific gravity of each cell with a hy-
drometer. {Draw in and expel the electrolyte two
or three times from the first cell to be tested to
adjust the temperature ofthe hydrometer to that
of the electrolyte.)
c. tfacorrected specific gravity reading of 1.225 at
80°F (27°C) is not obtained, replace the vent
caps and recharge the battery foilowing the bat-
tery charger manufacturer's instructions.
3. if the battery does not have removable vent caps,
check the condition of the battery as follows:
a. Checkthe stabilized open—circuit voltage of the
battery. For a 12 volt battery, any reading below
12.4 volts indicates the battery needs charging.
Disconnect both battery cables fromthe battery,
and allow battery voltage to stabilize for several
hours.
b. If the stabilized open-circuit voltage is below
12.4 volts, charge the battery following the bat-
tery charger manufacturer’s instructions.
Remove damp cloth from battery.
Reinstall battery in unit.
Replace battery holddown, and tighten securely. Do
not overtighten.
7. Connect positive (+) battery cable to positive (+) bat-
tery terminal.
8. Connect negative (-) battery cable to negative (-)
battery terminal.
8-8. GOVERNOR
The governor has been set at the factory and should not
require further adjustment.
8-3. ENGINE SPEED ADJUSTMENTS (Figure 8-1)
WARNING: ELECTRIC SHOCK can kill.
e Do not touch live electrical parts.
® Stop engine, and disconnect negative (-)
battery cable from battery before inspecting,
maintaining, or servicing.
MOVING PARTS can cause serious injury.
e Keep away from moving parts such as fans,
belts, and rotors.
OM-481 Page 28
HOT ENGINE PARTS can cause severe
burns.
e Wear protective gloves and clothing when
working on a hot engine.
Maintenance to be performed only by qualified
persons.
The engine speeds have been factory adjusted and
should not require frequent readjustment. After tuning
‘the engine, check the speeds with atachometer. With no
load applied, the weld/power speed should be 1850 rpm.
If necessary, adjust the speeds as follows:
1. Open and secure right rear side panel.
2. Loosen nut on end of engine speed adjusting screw
{see Figure 8-2).
3. Start the engine as instructed in Section 7-6.
4. Adjust the weld/power speed as follows:
IMPORTANT: All directions, such as clockwise and
counterclockwise, are with respect to the operatorfacing
the rear panel of the unit.
a. To increase weld/power speed, rotate the en-
gine speed adjustment screw clockwise.
b. To decrease weld/power speed, rotate the en-
gine adjustment screw counterclockwise.
5. When the weld/power speed reaches 1850 mm,
prevent the adjustment screw from turning, and
tighten the securing nut.
6. Stop engine.
7. Close and secure side panel.
8-10. REPLACING ENGINE BELT (Figure 8-1)
WARNING: ELECTRIC SHOCK can kill,
e Do not touch live electrical parts.
® Stop engine, and disconnect negative (—) bat-
tery cable before inspecting, maintaining, or
servicing.
MOVING PARTS can cause serious injury.
e Keep away from moving parts such as fans,
belts, and rotors.
MOVING PARTS can cause serious injury.
® Wear protective gloves and clothing when
working on a hot engine.
HOT ENGINE PARTS can cause severe
burns.
IMPORTANT: For the following procedure, all direc-
tions, such as clockwise and counterclockwise, are with
respect to the operator facing the rear of the welding
generator.
1. Remove rear panel.
2. Remove guard from engine pulley.
3. Loosen hex nut on alternator adjustment bracket.
4
Loosen hex nut on alternator pivot bolt, located on
underside of alternator.
Pivot alternator counterclockwise, and remove belt.
6. Install new belt, and pivot alternator clockwise until
belt is tight.
7. Tighten hex nut on alternator pivot bolt and alterna-
tor adjustment bracket.
8. Check belt for tightness according to Section 8-5.
9. Reinstall guard onto engine pulley.
10. Reinstall rear panel onto unit.
8-11. BRUSHES AND SLIP RINGS (Figure 8-2)
WARNING: ELECTRIC SHOCK can kill
® Do not touch live electrical parts.
® Stop engine, and disconnect negative (—) bat-
tery cable from battery before inspecting, main-
taining, or servicing.
MOVING PARTS can cause serious injury.
e Keep away from moving parts such as fans,
belts, and rotors.
HOT ENGINE PARTS can cause severe
burns.
® Wear protective gloves and clothing when
working on a hot engine.
Brush life is very good under most operating conditions.
The brushes and slip rings should be inspected every six
months or whenever excitation voltage is lost. Be sure
that slip rings are clean and brushes are free to move. If
the welding generator has been operating under ex-
tremely dusty or dirty conditions, increase the frequency
of inspection.
1/2 in. (12.7 mm)
Minimum
$-0234
Figure 8-2. Brush Replacement
Under normal use, the slip rings will discolor to a dark
brown. If a buildup of brush material is noted, it may be
necessary to cleanthe slip rings. Clean rings with a num-
ber 220 or finer sandpaper, and polish rings with crocus
cloth. Never use emery cloth because part of the emery
will embed itself into the rings and, in turn, destroy the
carbon brushes.
Replace the brushes if they become chipped or broken
or if less than 1/2 in. (12.7 mm) of brush material is left.
8-12. ETHER STARTING AID (Optional)
CAUTION: ETHER INJECTION WHILE
ENGINE IS RUNNING can cause engine
damage.
® Do not actuate ETHER STARTING AID while
engine is running.
The ether usedinthe cold weather starting aid systemis
contained in a replaceable cylinder located behind the
right rear side door on the center portion of the frame. No
indicator is provided to show the amount of ether left in
the cylinder; therefore, it is recommended that a spare
cylinder be kept on hand. Generally, the ether cylinders
empty ifthe engine fails to start in cold weather while uti-
izing the cold weather starting system.
WARNING: IMPROPER HANDLING OR EX-
POSURE TO ETHER can seriously harm your
health.
e Follow the manufacturer's safety instructions
on the cylinder when handling ether compo-
nents.
The cylinder can be weighed to determine the amount of
ether inside. The cylinder weighs 33 ounces (936 gr)
when full, and itweighs 15 ounces (425 gr) when empty.
To replace the ether cylinder, see Section 4-8.
IMPORTANT: Before installing the ether cylinder, clean
nozzle on ether cylinder and fitting into which the ether
cylinder is inserted. If dirt is present in either of these ar-
eas, the system may not work.
IMPORTANT: After installing or replacing ether cylin-
der, do not use or test ether start systemfor atleast 10 to
15 minutes to allow particles in fuel to settle to prevent
atomizer plugging.
8-13. SERVICING THE SPARK ARRESTOR
(Optional)
WARNING: ENGINE EXHAUST SPARKS can
cause fire.
9 Exhaust spark arrestor must be installed in
accordance with local, state, and federal regula-
tions.
® Stop engine before cleaning spark arrestor.
® (lean spark arrestor in a noncombustible en-
vironment.
HOT ENGINE PARTS can cause severe
burns.
e The exhaust system must be cold when serv-
icing the spark arrestor.
The engine exhaust system on this welding generatoris
not equipped with a spark arrestor. A spark arrestor,
maintained in effective working order, is mandatory if
this welding generator is to be operated in a National
Forest or on California Grassiands, brush, or forest cov-
ered land (see Section 4442 or California Public Re-
sources Code). Forother areas, check your state and lo-
cal laws. If a spark arrestor (optional) is desired, contact
your dealer/distributor.
Internal combustion engines operating in a highly com-
bustible environment are a common fire hazard. Glow-
Ing carbon particles blown out with the exhaust can re-
tain sufficient heat to ignite materials. While no practical
spark arresting device will stop all sparks, this device will
minimize fire hazards by removing and trapping most
solid particles provided that it is properly maintained.
OM-481 Page 29
Sed Tey
Inspect and service spark arrestor every 250 operating
hours.
Removal of the device from the exhaust system is not
necessary for servicing. Proceed as follows to service
the spark arrestor:
1. Stop the engine, and allow the exhaust system to
cool.
2. Remove left rear side panel.
3. Remove the cleanout plug fromthe spark arrestor. if
a crust has formed over the hole, break it loose with
a screwdriver or similar tool.
7.
Start the engine, and run it to blow collected par-
ticles out the cleanout hole. If particles are slow to
discharge, momentarily cover the end of the ex-
haust stack.
Stop the engine, and allow the exhaust system to
cool. |
Replace and secure the cleanout plug.
Reinstall and secure side panel.
SECTION 9 - TROUBLESHOOTING
PL АААННИ
9-1. GENERAL
ltis assumed that properinstailation has been made, ac-
cording to Section 4 of this manual, the operator is famil-
jar with the function of controls, the welding generator
was functioning properly, and the trouble is not related to
the welding process.
9-2. BOOSTER BATTERY JUMP STARTING
If it is necessary to jump start this unit, use the following
safety precautions and the step-by-step procedures in
order of appearance.
WARNING: BATTERY GASES OR A DAM-
AGED BATTERY can explode thereby shat-
tering the battery; BATTERY ACID can burn
eyes, skin, destroy clothing, and damage
other material; MOVING PARTS AND IM-
PROPER CONNECTIONS can cause serious
personal injury and damage equipment.
® Keep sparks, flames, cigarettes, and other ig-
nition sources away from battery.
® Ensure that all personnel are a safe distance
from batteries and clear of moving parts while
starting.
® Do not jump start a frozen or completely dis-
charged battery.
® Do not jump start a battery which has loose
terminals or one having evidence of damage
such as a cracked case or cover.
® Be sure that vent caps are tight and level on
both batteries and cover both batteries with a
damp cloth.
e Wearcorrecteye and body protection, andre-
move all metal jewelry.
e Keep jumper cables clear of moving parts.
.. 9 Ensure that both batteries are of the same
voltage.
® Do not jump start a trailer mounted welding
generator with the towing vehicle battery unless
the trailer is completely disconnected from the
towing vehicle.
OM-481 Page 30
e Do not jump start a vehicle mounted welding
generator from the vehicle battery.
e /f booster battery is installed in vehicle, do not
allow vehicle to make contact with welding gen-
erator case or frame.
® Do not jump start by applying power to weld
output receptacles or terminals.
e Do not allow jumper cables to contact any
other metal while attaching or removing cables.
Use properly insulated jumper cables of adequate
size.
Connect ends of one cable to positive (+) terminals
of each battery.
Connect one end of other cable to negative (-) ter-
minal of booster battery.
Connect remaining end of cable to welding genera-
tor engine block at least 18 inches (457 mm) from
battery (do not connect to weiding generator case,
frame, or equipment grounding terminal as damage
to equipment can result).
Wait at least one minute after connecting cables be-
tore starting engine.
Start engine following procedures outlined in Sec-
tion 6 (Sequence of Operation) of this manual and
allow engine to return to idle speed. If the unit does
not start after cranking for twenty seconds, stop the
jump starting procedure. More than twenty seconds
seldom starts the engine unless some mechanical
adjustment is made.
Remove jumper cable from engine block.
Remove other end of same cable from booster bat-
tery negative (-) terminal.
Remove other Jumper cable from welding generator
battery positive (+) terminal.
. Remove remaining end of cabie from booster bat-
tery positive (+) terminal.
. Discard damp cloths.
9-3. OVERLOAD PROTECTION
WARNING: ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
e Stop engine, ahd disconnect negative (—} bat-
tery cable from battery before inspecting, main-
taining, or servicing.
MOVING PARTS can cause serious personal
injury.
© Keep away from moving parts such as fans,
belts, and rotors.
HOT ENGINE PARTS can cause severe
burns.
e Wear protective gloves and clothing when
working on a hot engine.
INCORRECT FUSE can damage unit.
® Be sure replacement fuse is same size, type,
and rating.
A. Circuit Breakers CB1 and CB2 (Figure 6-1)
WARNING: Read and follow safety informa-
tion at beginning of Section 8-3 before pro-
ceeding.
Circuit breakers CB1 and CB2 protect the 120 and 240
volts ac auxiliary power duplex receptacles RC1 and
RC2fromoverioad. CB1 and CB2 are located behind the
front panel lower access door, above the dupiex recep-
tacles RC1 and RC2 (see Figure 6-1). Whenever an
overload occurs and either CB1 orCB2 opens, both RC2
and half of the duplex receptacle RC1 will not operate. If
CB1 and/or CB2 open, locate and correct the problem,
and manually reset the circuit breaker(s).
B. Unit Wiring Protection Circuit Breakers CB3
And CB4 (Figure 6-1)
4 WARNING: Read and follow safety informa-
tion at beginning of Section 9-3 before pro-
ceeding.
Circuit breakers CB3 and CB4 protect the unit wiring
from overload and damage. CB3 and CB4 are located
behind the front panel lower access door, right of the RE-
MOTE 14 receptacle RC3. If CB3 opens, 115 volts ac
output to pin | of RC3 is stopped, and the wire feeder
stops. If CB4 opens, 24 volts ac output to pin Aof RC3 is
stopped, the wire feeder stops if it is using 24 volts ac,
and the remote contactor will not function. If CB3 and/or
CB4 open, locate and correct the problem, and manually
reset the circuit breaker(s).
C. Replacement Of Low Qil Pressure/High Oil Tem-
perature Shutdown System Fuse F
WARNING: Read and follow safety informa-
tion at beginning of Section 9-3 before pro-
ceeding. |
1. Remove securing screws, and open upper front ac-
cess door.
2. Locate shutdown switch MS1 on right, rear side of
front access door.
3. Locate fuse F on bottom of shutdown switch MS1.
4. Remove and check fuse, and replace if necessary.
5. Close and secure front access door.
9-4. CIRCUIT BOARD HANDLING PRECAUTIONS
WARNING: ELECTRIC SHOCK can kill
® Do not touch live electrical parts.
® Stop engine, and disconnect negative (—) bat-
tery cable from battery before inspecting, main-
taining, or servicing.
HOT ENGINE PARTS can cause severe
burns.
® Wear protective gloves and clothing when
working on a hot engine.
CAUTION: ELECTROSTATIC DISCHARGE
(ESD) can damage circuit board compo-
nents.
e Put on properly grounded wrist strap BE-
FORE handling circuit boards.
e Transport all static-sensitive components in
proper static-shielding carriers or packages.
® Perform work only at a static—safe work area.
INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
® Be sure that plugs are properly installed and
aligned before closing access door.
EXCESSIVE PRESSURE can break circuit
board.
e Use only minimal pressure and gentle move-
ment when disconnecting or connecting board
plugs and removing or installing board.
If the Field Current Reguiator Board PC1 or the CV
Regulator Board PC2 is not working, remove securing
screws fromtop front panel access door {top hinged por-
tion of nameplate and front panei), and remove and re-
place circuit board(s).
9-5. TROUBLESHOOTING (Tables 9-1 Thru 9-3)
WARNING: ELECTRIC SHOCK can kill.
® Do not touch live electrical parts.
e Stop engine, and disconnect the negative (-)
battery cable before inspecting, maintaining, or
servicing.
MOVING PARTS can cause serious injury.
® Keep away from moving parts such as fans,
and rotors.
HOT ENGINE PARTS can cause severe
burns.
® Wear protective gloves and clothing when
working on a hot engine.
Troubleshooting to be performed only by quali-
fied persons.
The following tables are designed to diagnose and pro-
vide remedies for some of the troubles that may develop
in this welding generator.
OM-481 Page 31
a
Use these tables in conjunction with the circuit diagram
while performing troubleshooting procedure. If the
trouble is not remedied after performing these proce-
dures, contact the nearest Factory Authorized Service
Station. In all cases of equipment malfunction, strictly
follow the manufacturer's procedures and instructions.
Table 9-1. Weld/Power Troubleshooting
TROUBLE
PROBABLE CAUSE
REMEDY
No weid output.
AMPERE RANGES switch $3
is between positions.
Place S3 in proper position (see Section 6-1).
OUTPUT (CONTACTOR)
switch S5 in REMOTE 14 posi-
tion and Remote Contactor de-
vice not connected.
Place S5 in ON position, orinstall Remote Con-
tactor Control device.
Incorrect or poor connection to
REMOTE 14.
Check and secure connection to RC3.
Circuit breaker CB3 or CB4
open (GMAW only).
Reset CB3 or CB4 (see Section 9-3).
Poor contact between siip rings
and brushes.
Clean slip rings (see Section 8-11).
Replace brushes according to Section 8-11.
Circuit board PC1 and/or PC2.
Check and replace PC1 or PC2, if necessary
(see Section 9-4).
Erratic weld output.
Loose or dirty connections.
Check connections both inside and outside the
unit.
Check leads and contact of AM-
PERE RANGES switch S3.
Tighten loose connections or replace S3.
Connection at work.
Check connection. Be sure connection ts clean
and tight. |
Damp electrode.
Use dry, properly stored electrode.
Circuit board PC1 and/or PC2.
Check and replace PC1 and/or PC2 if necessary
(see Section 9-4).
High welding output voltage.
High engine speed.
Check and adjust engine speed according to
Section 8-9. (Maximum voltages should not ex-
ceed 132 volts for single-phase power and 264
volts for three-phase power.)
Circuit board PC1.
Check and replace PC1, if necessary (see Sec-
tion 9-4).
Wire feeder inoper-
ative.
Circuit breaker(s) CB3 and/or
CB4.
Reset CB3 and/or CB4 according to Section 9-3.
Table 9-2. Auxiliary Power Troubleshooting
TROUBLE
PROBABLE CAUSE
REMEDY
No output at 120 Volts AC re-
ceptacle RC1 and/or 240
Volts AC receptacle RC2.
Circuit breaker CB1 and/or
CB2 open.
Reset CB1 and/or CB2 (see Section 9-3).
Poor contact between slip
rings and brushes.
Clean slip rings {see Section 8-11).
Replace brushes according to Section 8-11.
High auxiliary power output
voltage.
High engine speed.
Check and adjust engine speed according to
Section 8-9. (Maximum voltages shouid not
exceed 132 volts for single-phase power and
OM-481 Page 32
264 volts for three-phase power.)
Table 9-3. Engine Troubieshooting
TROUBLE
PROBABLE CAUSE
REMEDY
Engine does not stan.
Out of fuel.
Fill fuel tank, and air vent fuel system (see En-
gine Manufacturer's Manual.)
Battery problem.
Check engine battery charging system accord-
ing to engine service manual (not supplied with
engine).
Inspect electrical system (see Section 8-1). If
trouble is isolated to battery, replace it.
Jump start the engine using approved safety
practices and booster battery (see Section
9-2).
Engine Control switch S1.
Check S1, and replace if necessary.
Oil Pressure switch/gauge or
Oil Temperature switch/gauge
activated, or other engine
trouble.
See Sections 6-11 thru 6-13; see Engine Man-
ufacturer’s Manual (F4L-912 engine).
MS1 fuse F.
Check and replace F, if necessary (see Section
9-3).
Engine suddenly shuts down.
Broken engine belt it CHECK
COOLING SYSTEM/ALTER-
NATOR indicator light PL3 is
on.
Check and replace engine belt according to
Sections 8-5 and 8-10.
High oil temperature.
Check engine oil level and add oil if necessary;
check for cooling air flow obstructions.
Low oil pressure.
Check engine oil level, and add oil if neces-
sary.
MS1 fuse Е.
Check and replace F if necessary (see Section
9-3).
OM-481 Page 33
"a
== =
OM-481 Page 34
NOTES
SECTION 10 — ELECTRICAL DIAGRAMS
wesbeig undo “1-01 weabeiqg
LS 2 15 ОО; РКО ВУ IV AR 15
92-280 LEL-QS "ON WEJBeIQ HN неон
r Xx I 3 0 3 8 Y
"or fes LP ES if 16 ES 19 6 ES 4
0.0. 20.20. 0.0. 20.5. 9: 6. 6 00 0 DN CO 00 04
NA 1 #8 4 0 4 H KH 1 3 PMP H 6 14 3 0 5 a у pa | > or
Wu
Arild
007 49 о ве ре Ар 81 8 JDA El
9 0 0 0 Oo Oo 0 0 0 Ol —
A rr WH 8B 4 3 9 3 a vw iw —
HS \ —
ZAILISOd HAILYSZH TYNIMREL (5) = +
о o 4. OL COST = X
Hi oF
Г + x 9 Ч
= ar “a 19 x|x у ENTRAR
| + Г X E
x|xix|x E
x|xIx|x I A
y 15
215134]
OM-481 Page 35
-
м
O += «oO Oa
| ds — MEL A A дол
A YE YY
Lei, Lied > I 5 |
ra Zi TS x HOLT ALND -
eus saa A I | о __ Par © # <
e pa y oh Hd Dad af” * 24 =<
«LL to) [CL 1 rl | FH
> + _
Ро || г и ar = я > ‹
141 7“
E {+ |
IZ Ze <
| + E. <
Î F7 . <
| AFF
| pr 3 ES |
E 6 i
a
| POD АР
“ Ye й
rl Dr я Mr »r
ААА ИАН АА ИМ а … ‚
pr ; :
LA | Ya TE | IF x £l a ar уу ИЯ or a 0 TF7 o
“a Li H
ES
OM-481 Page 36
ENGINE
GND. STR
N
“
1
- ™
4
DN
1 1
_
LLLALS:
LA 125
| ZLALS
| 218 (3;
| LALS
| 318 (5;
424 LEHD STUD
100A IRC]
| 1OIALDST -F
GA4A[2T-N}
GALO
P0AITOS
1304 {CB
Ley.
O
STARTER
wELD
STATOR
NEGATIVE
POSITIVE
PUS.
BATTERY
NEG.
GND. BATTERY
STUD FRAME
—É o — — — — — — Ji мн не сн = о == о ===
Diagram 10-2. Wiring Diagram
OIL OIL
PRESS TEMP
GNO .STUD
SLIP RINGS
Wiring Diagram No. D-132 264-B
OM-481 Page 37
Circuit Diagram No. SB-115 028
Diagram 10-3. Circuit Diagram For Field Current Regulator Circuit Board PC1
> A REG. OUT
—>e
G +24 V. INPUT
WELD NEG. D
~ C2
WELD POS. H <
VOUT
„Со
VRI
-10 У.
Circuit Diagram No. SA-114 318
Diagram 10-4. Circuit Diagram For CV Regulator Circuit Board PC2
OM-481 Page 38
UC НОЛАН
SECTION 11 — PARTS LIST
OM-481 Page 39
il Y
= 4
90
87
x
Fig 11-3
Figure 11-1. Main Assembly
OM-481 Page 40
50-134 499
OM-481 Page 41
item Dia. Part Do
No. Mkgs. No. Description Quantity
Figure 11-1. Main Assembly
1 Fig 11-2 PANEL, frontw/components ............. iii... 1
2 118 790 ANGLE, strainrelief ©... ee a aa aa 1 1
3 Fig 11-4 CONTROL BOX Le ee a a a da ae 0 1
4 087 341 BUMPER, door1.000 OD x .750high ......................... 6
5 118640 UPRIGHT, front ............ 2.2.2.0... e. Lea La Le Late 1
121699 SPACER, cover ...... ee, 2
086863 SCREW, cap stl hexwhd slflkg 375-16 . ....................... 4
602213 WASHER, lock sti split .375 .......... een 4
601 871 NUT, stlthex jam .375-16 .......... a. 4
6 Z1 117270 =— REÂACTOR, AC i, 1
7 131 188 FRAME, mtg reactor ............ 2... e... 0aadaCavaner 1
007025 SCREW, cap stl hexhd .625-11 х 1.250 ........................ 4
602 218 WASHER, lock stl split .625 ........... .......02. 2... e... 4
085 980 NUT, stl hex full fnsh .625-11 ........... ii. 4
8 R3 128862 RESISTOR, WW adj 375W 50 ohmw/mtg bracket ............... 1
9 118 643 UPRIGHT, center. RR KR a 0 1
; 086 863 SCREW, cap stl hexwhd slflkg 375-16 ............ cco... 2
10 017479 SEAL, weatherlifteye ......... i ian 2
11 108 081 TERMINAL PROTECTOR, batterypostmtg .................... 2
12 134456 CABLE, batneg ...... i, 1
13 118644 HOLDDOWN, battery ....... ee. 1
14 BAT 070859 BATTERY, stor 12V 750crk 185 RSV .......... 2... 0... 1
15 032452 CABLE, bat pos 33.000 ................ 022... adroredo 1
16 010460 STUD, sti .312-18 ......1L 1110 1e LL La a A a aa a Aa aa ae 1
17 CR2 080 104 — НЕСАУ, епс!12\ОС $Р$УТ ................................. 1
18 116978 BASE erre adan adorereenecareaeaaoa. 1
19 131688 COVER, top ...............2s0000:.eca.errerec ceden nea 1
20 117 486 PIPE, exhaust ............. 22. .0000,eera aan oe. 1
21 118073 CAP, rain .......... recederonaaonoarerecoreroonaron. 1
22 108487 LABEL, warning falling equipment etc ................... 2
131752 PANEL, engine LH .......... 2... ..eerárereveerececar or. 1
23 131 186 PANEL, end engine ................es0esmrec0are dere, 1
24 004 130 BRACKET, support door 0... ee. marereci e... 1
25 121509 LABEL, waming do not run engine etc ................. 2
26 +131222 DOOR, side ........ 0.0... a0receceaacecarnanooo on. 1
120 629 LABEL, diesel engine maintenance ........................... 1
27 119 861 LATCH, paddle seriesw/lock . ................. ee 1
28 119 851 PANEL, rocker ...... a a 4 4e da ee aa ee ea a a a a aa 1
29 S11 118067 SWITCH, vacuum air flIOW. recorra. 1
30 089 129 PIPE, aircleaner NR La a aa a ae 1
31 133066 HOSE, elbaircleaner ........... iin. 1
32 045657 AIRCLEANER, intake (consisting of) ......................... 1
33 021 114 -CLAMP ASSEMBLY ........ 2.0... 0000 een. 1
34 021 115 : BAND, Mg RR a A a A La Lee 1
35 *020 319 ELEMENT 000 a a a a a a a a a a ea ae aa ae 1
36 021117 NUL WING «ee Aa a 1
37 021116 CAP dust ... aa AAA Lee AA a ea ae a a a a ne 1
004 115 - BAFFLE, dustcap .......200 000024 aa a a 4 4 ee eee aa ea eee 1
38 010863 CLAMP, hose 2.062-3.000clpdia ..........c.c ii... 3
39 133067 HOSE, elbaircleaner ............ in 1
40 023313 CLAMP, hose 3.250-3.000cipdia ............ iii... 1
41 601945 SCREW, cap stihexhd 625-18 x4.000........................ 4
42 071 731 \МАЗНЕВ, На! 5! .656 1Ю х 2.250 ОД ......................... 4
43 116 707 SUPPORT, frontengine ........... ii... 1
44 602246 WASHER, flat sti std .500 ............ ci. 4
45 071730 TUBING, sti .875 OD x 12ga wall x 2.375 ...................... 4
46 071830 RETAINER, mount eng/gen .............oeee.rr0erecer een 4
601 851 NUT, sti sif lkg hex reg .625-18 ............. 2... e 4
OM-481 Page 42
item Dia. Part I .
No. Mkgs. No. Description Quantity
Figure 11-1. Main Assembly (Continued)
47 089 351 FITTING, pipe brs plug hexhd 1/2NPT ................. ...... 1
48 117 802 FITTING, oil drain iii eee eee ens 1
49 088 946 HOSE, 101n1/2dia ........_...—.e.ee_eeerereeararereredaanar—o 1
50 602904 FITTING, pipestlelbst 500NPT ........... iii... 1
51 118 452 FITTING, adapteroildrain . ............. ci... 1
52 034116 CLAMP, stlcush 825diax 468 ............ cine 0» 2
53 131322 SHUTDOWN KIT, rsv type govenor ..........—.e_ ercer. 1
54 Fig 11-7 GENERATOR ......... 7. 0srerirrareererervrernvecerernedo 1
55 130435 ENGINE, deutz dsl elec (consisting Of) ........................ 1
56 066 271 *V-BELT 2.n,ecrrarenraaooaracaeaororame, ee eee aa ne 1
131208 STOR throttle... i ee eerie ea 0 1
010143 CLAMP, nyl .375cipdia..........._—.omeeerrevreevoeroe re reves 2
010 021 CLAMP, stl cush .5e2dia (ground load support) .................. 1
602 247 2 WASHER, flat sti sae 500 .......... a a aa a 111 100 1
57 119 801 BAFFLE, airmanifoldexhaust .................. ci... ... 1
58 134550 BAFFLE, cover iti i tee eee ete ees 1
59 132712 PIPE, muffier extension elb 1.875 OD ....0.000 1
60 119 797 BAFFLE, airmanifoldexhaust ............... ii... 1
61 117219 PANEL, side © RR RR 0 aa ea ea een SA 2
62 071126 HOSE, nprnbrd No. 1 x .375 1D (order by ft) ...............—..... 6ft
023562 CLAMP hose .312-875clpdia ........... ci. 2
63 099542 CLAMP hose 645-828clpdia ........... cc. iin. 3
64 081646 FITTING, brs parbed M3/8tbgx 1/4NPT ....................... 3
65 010678 FITTING, pipe brs elb st 1/4NPT E .......... ii... 2
66 117227 BRACKET, mtgfuelfiter ............ee..e-—.—vreve0raoerererece.. 1
086863 SCREW, cap sti hexwhd slilkg 375-16 ........................ 2
602213 WASHER, lock stl split 375 ......... i iii eue 0 2
601 871 NUT, st! hex jam .375-16 RR 2
67 062342 SEPARATOR, fuel filter á water ............e—.———_eeeeracaro. 1
68 083 553 BASE, filter fuel wadapter .......12021100 001 a LL ae ea aa aa 40 1
69 604550 HOSE, nprn brd No. 1 x .187 1D (order by ft) .................... 4f
70 089120 = CLAMP hose .375-.450 clp dia ........224222 212 4e Lea ra aa a ae 1
71 073432 FITTING, brs barbed M 3/16tbg x 1/8NPT ...................... 1
72 010869 FITTING, pipe brs bushing 1/4 x 1/8NPT ...................... 1
73 119486 TUBE, pick-upfuel ............. 0 iii... 2
74 131 189 PANEL LAYOUT firewall ..... iii eerie a 1
75 010494 BUSHING, snap-innyl1.375ID ......... iii... 1
76 026 947 sSTAND-OFF, insuf .250-20 x 1.0001g ............. _co_e.erean... 5
77 131 127 BRACKET, rect RH 1.220100 0044 41 a Va a A Le A ea aa ea a a a a Le 1
78 SR3 131805 RECTIFIER, SI3ph 300A ee ian 3
79 116 981 BRACKET, rect LH ............ee—esaooavarvaoenraroaoanerao 1
80 131 124 SHIELD, heat lower RH .................. 2. eee. 1
81 131125 SHIELD, heat lower LH ............. 2... 0000irxr.ererie. a 1
82 131123 SHIELD, heatupper................—. e... ..r0r0receaaea. 1
83 SHUNT 65072426 SHUNT, meter 50MV 1000A .......... 2.2, naa. 1
84 122354 GUARD, splash fuel ............. iia. 1
85 107343 2 GROMMET, rbr neck filter fuel .............. i... 1
86 024 035 CAP tank fuel ..... .. 2... 00nadonrenaoooonnecó 1
87 Fig 11-3 PANEL, front lower w/components ........................... 1
88 121823 LABEL, warning do not lift ................. 0. ui... 1
89 010 914 HANGER, minerallic No. 5 ................—.emererec0areare.o 1
90 046392 = LABEL, warning general precautionary .............2442040 4000 1
91 +127 304 DOOR, front lower ................. .. ereevardszoonecorvedoo 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
“Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-481 Page 43
a
E
OM-481 Page 44
ee) UN
E
A
17
16 50-134 500
15
Figure 11-2. Panel Front w/Components
tem Dia. Part as ;
No. Mkgs. No. Description Quantity
Figure 11-2. Panel, Front w/Components (Fig 11-1 item 1)
53 131 213 SWITCH RANGE/CHANGEOVER ........... 5..5, л.с инки
118 340 PANEL, front upper ... co. i i ee
R1 072 462 POTENTIOMETER, w/shaft lock (consistingof) ..................
072 590 - LOCK, shaftpot .375-32x.250 ................ eee 2 00
604 645 NUT, stl hex .375-32 1.111000 041 La 44 La ee A ee a A a ea a a a a a a a 2e
Sa +021 467 SWITCH, tgl SPST MC 3A 250V oo 4 LL aa ana
54,5 011 609 SWITCH, tgt SPDT 154 125VAC iii,
S6 011 611 SWITCH, tgIDPDT 15A125V ea
605 321 NUT, st! hex 468-32 ....... iii ieee
602 222 WASHER, lock stlintltooth . 437 ..............................
S1 128 019 SWITCH, ignition 5 posnw/outhandle .........................
132 446 PLATE, indent control rating .............—..e.0.0 0. a0res.io..
021 385 BOOT, tgl switch lever ............. e... e .ericómenaenodoo.
119 974 LEVER, switch chrome .............eecra.redeo.ovararooce,a ma
лом о © 0 М О (1 № © 0
e YAA =& HA SA О POOR) bh bh =& =& = =А = а (д) A A CI O) 4 PN) AA AAA 4
FG 118 066 GAUGE, fuetelec12Vnegard ........ 0.
119 482 SENDER, fuel gauge (locate on main assembly, not shown) ........
16 A1 118 060 METER, amp DC 60-0-60 .................. 0. 00000.
17 128 870 GAUGE, pressure oil 25-30 PSI . ...... ii 46
128 829 KIT, oil line 44.000 in 1/8NPT x 10mm .......... cou... ...
18 129 837 GAUGE/SWITCH, tempoilmech250deg . ......................
19 HM 118 058 METER, hour 12-24VDC ie i ieee
20 082 788 HOLDER, lightindonly ......... iii...
21 082 789 LENS, light ind red .............. . 0 RER a au
22 PL1,3 7048155 BULB, incandflgbase 12V .......... a La La a ae
23 097 926 KNOB, pointer ........10220 00044114 Lea a a LL La Aa na
24 010 647 PIN, spring CS .156 x 1.250 .. Re
25 090 231 HANDLE, switch range ...............eomreceeereerererenda nen
26 A2 131 781 METER, amp DC 50MV ............. ees
27 V1 131 753 METER, volt DC 0-100 .......111211 141111144441
28 NAMEPLATE, (order by model & serial number) .................
29 022 289 TUBING, stl .3120D x 187 1D... ee i |
30 +021 385 BOOT, tal switch lever ..................... . erararerecoo
+ art Of Optional 041 480 Ether Starting Aid
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-481 Page 45
OM-481 Page 46
21
22
21
19
SC-134 501
Figure 11-3. Front-Lower w/Components
tem Dia. Part En
No. Mkgs. No. Description Quantity
Figure 11-3. Front-Lower w/Components (Fig 11-1 Item 87)
1 038 612 TERMINAL ASSEMBLY, pwr output (consisting of) ............... 2
2 601 840 NUT, brs hex 500-13 ..... 2 ..ra00rrerere rearme. 4
3 601 839 NUT, brs hex 500-13 ..... i. 2
4 038 847 -BUS BAR, termpwroutput .................... eae 1
5 NEG/POS 038613 - TERMINAL BOARD, pwroutput .......... ci... 1
6 038 900 - STUD, brs .500-13 ..........reeesaredororedoonove earn. 2
7 602 247 - WASHER, flat stI SAE 500 . .. .... ea aa 0e 2
8 605 787 - WASHER, lock stlintitooth 500 .............c. oii. 2
601 976 SCREW, cap stl hexhd .500-13 x 1.500 (bus barto terminal) ........ 2
044 942 NUT, locking .500-13 (bus bartoterminal) ...................... 2
9 C1,2 080 894 CAPACITOR, cer disc .O1uf 1000VDC ............... 25...55... 4
10 131 122 PANEL, front JOWer .......e..oc_eoeecxerrarerereramarererver a 1
11 602 221 WASHER, lock stl inti tooth .375 ..............—.—.—.—.—.—.erívrere.. 4
12 604 645 NUT, sti hex .375-32 ................0.0erreereeravaravoao ra 4
13 CB1,2 053 283 CIRCUIT BREAKER, man reset 1P 15A 250V ..............enre. 2
14 RC2 604 103 RECEPTACLE, strdx grd 2P3W 15A250V ..................... 1
025 234 PLUG, str grd 2P3W 15A 250V |
15 RC1 039 864 RECEPTACLE, strdxgrd 2P3W 125V .. iii 1
073 690 PLUG, str grd armd 2P3W 15A 125V
16 VRi/R4 046819 SUPPRESSOR ni mra.sresararrareoarererevervrorero ee. 1
17 RC3 109 769 RECEPTACLE, 14skt 97-4102A-20-275 .........—............... 1
109 766 PLUG, 14 pin 97-4106A-20-27P
109 770 TERMINAL, male 1 pin sz 45 16-22 wire
116 964 CLAMP, cable 97-3057-1012
18 020 279 CLAMP, stl cush .750dia x .281mtghole . ....................... 1
19 C34 083 432 CIRCUIT BREAKER, manreset 1P 10A250V ................... 2
20 C10 080 894 CAPACITOR, cerdisc .01uf 1000VDGC ............ e. eo... a a ee 1
21 132 661 CAPACITOR ASSEMBLY, (consistingof) ....................... 2
C3-9,11 080 894 - CAPACITOR, cer disc .01uf 1000VDC ........................ 4
22 3T 038 601 BLOCK, term 30A 9P 11.111110 04 La aa ane ee a La aa a ae 1
038 866 CONNECTOR, blk 30AS80deg ......... ci... 9
23 083 030 STUD, brs grd .250-20 x 1.750 . ... oe 1
24 010915 WASHER, flat brs 250 ID x 625 OD 112010222020 111 Le nana 5
25 601 836 NUT, brs пех 2250-20 LL 1111101440 a La a 4 4e 4 A ea a a ae aa a 3
26 010 916 CONNECTOR, clampcable .750 ......... ccc... 1
27 132 276 PLATE, ident control ratinglower ...........c...... ive... 1
28 039 885 CAP, dust connector 9760-20 ............... 5..5. ........... 1
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-481 Page 47
"a -
item Dia. Part
No. Mkgs. No. Description Quantity
Figure 11-4. Control Box (Fig 11-1 Item 3)
1 2T 129 939 BLOCK, term 10A 19P ee a 20 1
2 131 339 ENCLOSURE, control box ............eoececoriore avere en 1
3 CRT 044 588 RELAY, encl 12VDC 3PDT ...... een 1
4 020 225 CLAMP, nyl 875clampdia ................... ............... 1
5 MS1 118 072 SWITCH, magnetic shutdown 12VDC (consisting of) .............. 1
F “048 317 * FUSE, minat gl 14A 32V ........... Ce eee eee 1
6 122 216 CONNECTOR, blk 15A .........111111 11011111 LL 2
7 17 098 828 BLOCK, term, 10A 10P ............ a. 1
8 SR1 035 704 RECTIFIER, integ 30A 600V .......0111 01111 La a a La Le Lee 1
9 D1 128 299 DIODE, board ......... eerereraererene, 1
10 PC2 114 832 CIRCUIT CARD, voltage regulator (Fig 11-58) ................... 1
11 PLG2 115 092 HOUSING PLUG & SOCKETS, (consistingof) .................. 1
113 746 - TERMINAL, female 1skt 18-24 wire .. .... ene. 8.
12 110 375 STAND-OFF SUPPORT, PC cardNo.6screw .................. 8
13 PC1 133 757 CIRCUIT CARD, field current regulator (Fig 11-6) ................ 1
14 PLG1 135 275 HOUSING PLUG & SOCKETS, (consistingof) ................... 7
; 114 066 - TERMINAL, female 1skt 20-14 wire .................. ...... 15
15 603 107 HOSE, nprn slit bk .156 ID x .343 OD (orderby №) ................ 1ft
16 SR2 097 353 DIODE/SCR, bridge intg 25CR 3 diodes ....................... 1
17 R2 130 515 RESISTOR BOARD ............ 020.0. 00 00d0adddueuo ao 1
1 2
Fig 11-570
58-134 502
*Recommended Spare Parts.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-481 Page 48
Figure 11-4. Control Box
Dia. Part Co :
Mkgs. No. Description Quantity
PC2 114 832 Figure 11-5. Circuit Card, Voltage Regulator (Fig 11-4 Item 10)
A1 096 275 IC, linear 324 1.112121 0 00444 4 4 442 44 4 4 Ve 4 40 0 a 4e 4 4 8 6 0 a 1 KR 0 1
C1-3 083 182 CAPACITOR, cer luf SOVDC ....1002 4111014 4424 4 a ea 1e 1 2 4 a 10 046 3
C45 080 507 CAPACITOR, tantim 22uf 15VDC ee ieee ees 2
C7 072 935 CAPACITOR, elctit 33uf 35SVDC 1.111.020 21202101 14 ea ea 1114000 0 1
D1 028351 DIODE, ig .020A 75V SP ............e..er00ree000re ea Ds 1
R1 009 172 POTENTIOMETER, cermet 25/T .E5W 50K ohm .................... 1
R2,3,11,15 093 037 RESISTOR, CF .25W 47K ohm 110040441144 4 444 4 40 4 4 14 4 046 4
R4 049 015 RESISTOR, CF .25W 10 meg ohm ...............0e0rerearraene 1
R5 052152 POTENTIOMETER, cermet 25/17 .5W 1 meg ohm ................... 1
R6,7,16 000 885 RESISTOR, CF .25W 10K ohm .............0.e.searererererren, 3
R8,10,12,14 044 789 RESISTOR, CF 25W 100K ohm .... i i a LL Le 10 4
R9,13 039 336 RESISTOR, CF .25W 220K ohm ........_......ree0s2smererenvera, 2
R17 035 824 RESISTOR, CF .25W 270 ohm RR ea 1
R18 000 038 POTENTIOMETER, cermet 25/T 5W2Kohm ..................... 1
RC1 114934 TERMINAL, header 8 pin . .......c. ee ieee 1
U1 113 782 IC, interface 7660 ..............0..QoeQexecrorereerar0de recrea vera. 1
VR1 091256 1C,linear 317L ........... 2... ..00revrecoreererenrecreareraa. 1
(4
+ fg a pes R39 г RS +
Sp a ES
R6|— == с —
[—1 Ré2 105 E_ D6 pz7
Г но [I R3| CT
Гр р T7 OÙ R36/ 328 se! ç
[1 R29 [1] R34 Г
CM D4 _ mr ©
CU r La R38 я x
oA 2
са юз о! бою =
[1 RS + D8 E _ =
1 9 | C4 КОР «C ad a
Of +
CM D2 R34 К Lal RI
[1 re [05 [J RI 1 ——Ral Mm
[>] RIO RI Ul LS R42 Oo
7 = Po 3 ~_Dl2 MI
Ria 09 + о
= Ris го К I
JL че = 4%
I 2 O! RES
N CD С —e 17° A E
| Fc — С RI6
D + — > (773 RIB
e: 4 | RAE O GA
я D CIDO H Gr—F Е >
ez с12
т 3 O
+ a + SB-114 335
M38 8S ASSY 9D E BA Re
Figure 11-5. Circuit Card, Voltage Regulator PC2
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-481 Page 49
"en -
OM-481 Page 50
©
ASSEMBLY
0 = —
NITO O O
Yor
NÓ
“OD Ul
| sa —r
= ow ©
OM — W A C7
yr — — — — VR
КОКО НОЕ Е
DC B A
& = &
E
Figure 11-6. Circuit Card, Field Current Regulator PC1
SC-114 831
Dia.
Mkas.
PC1
Part
No.
133 757
Description
Quantity
Figure 11-6. Circuit Card, Field Current Regulator (Fig 11-4 Нет 13)
A1
C1
C2-7,9,11,13
C8
C10
C12
C15
R10
R11,14,16,17,
20,24,25
R12
R13
R15
R18,27
R21,23,28
R22,26
R29
R33
R34
R37,40
R38
R39
R41
RC1
SR1
VR1
VR2
096 275
114 067
073 739
035 832
000 859
072 130
091 791
028 351
026 202
037 399
037 203
084 269
037 200
039 355
035 842
082 178
039 335
039 326
039 325
038 584
035 888
082 179
108 437
039 332
035 827
035 828
039 337
035 887
035 896
028 285
035 825
039 106
035 829
074 060
089 318
009 173
035 824
074 104
114 064
035 841
081 832
091 256
IC, linear 324
CAPACITOR, tantim 1.5uf 20VDC
CAPACITOR, cer .1uf 50VDC
CAPACITOR, polye film .0015uf 100VDC
CAPACITOR, elctit 220uf 35VDC
CAPACITOR, tantim 1uf 35VDC
CAPACITOR, tantim 15uf 35VDC
DIODE, sig .020A 75V SP
DIODE, 1A 400V SP
DIODE, sig .0085A 60V SP
DIODE, zener 6.8V 1W
IC, interface 11L1
TRANSISTOR, NPN 200MA 40V
яп. ине не Ww ен ини ® 2A ® m & EN WN EN m a ® a & wm ¥ 4% # ® ни вая ва ва в mw uw m
и и + а канон он ов я кол & о кон 1 #% 1 6 * 4 w EN FF и но a =m ня мон он в п хи ха ти
TRANSISTOR, UJT 15MA 40V
TRANSISTOR, PNP .6A 40V
POTENTIOMETER, cermet 25/T .5W 10K ohm
RESISTOR, CF .25W 47K ohm
RESISTOR, CF .25W 68K ohm
RESISTOR, CF .25W 82K ohm
RESISTOR, CF .25W 470K ohm
RESISTOR, CF .256W 2.2K ohm
POTENTIOMETER, cermet 25/T .5W 25K ohm
RESISTOR, CF .25W 4.7K ohm
RESISTOR, CF .25W 15K ohm
RESISTOR, CF .25W 10K ohm
RESISTOR, CF .25W 240 ohm
RESISTOR, CF .25W 330K ohm
RESISTOR, CF .25W 3.3K ohm
RESISTOR, CF .25W 33K ohm
RESISTOR, C .5W 100 ohm
RESISTOR, CF .25W 1K ohm
RESISTOR, CF .25W 470 ohm
RESISTOR, CF .25W 1.5K chm
RESISTOR, C 5W 1K ohm
RESISTOR, WW fxd 5W .1 ohm
POTENTIOMETER, cermet 20/T .5W 5K ohm
RESISTOR, CF .25W 270 ohm
RESISTOR, C 1W 1.5K ohm
TERMINAL, header 15 pin
RECTIFIER, integ 1.5A 200V
IC, linear 78M 15
IC, linear 317L
. PK U a N POE EEE OR EEE # 4 uw + nm
т НН ото + FE 1 = 7 = x HE x 4 0 ов окт он каш оц Мой а нон ок они ов нон ноя та на =m
= =: x = = = в дл 4 3 + + очном окон окон окон от ока в
« к не я ов # оо Ra ¥ =m # * 4 *
+ в и ши чин ин ан к на чи ня наи на
4 и + 4&4 + ®m = шин mE ян о & § = + F #% но он ¥% & ни тан т аи Ww a ®m a
и = в =: ® я + + § ®% 4 # 4% & тн w 2 ™W BB OE BB OW a BB EN BB 47 ®B 4 ¥ & +
+ + 1 ¥* UT к от о = о = о я" о = = A 1 = a
= =: = § = = x & FF & F ак нон во
4 4 # 4 # & mW EN WN a w a w a * =m a §
ok 4 EB OB A 4 # 4 & A A =m om om om OF OW ® & ® NB
HN OH + & и аа к ян к от = ян на
. = ®* = =: = ®» 4 нов = кн оля
+ = + HE + 4 * 4 F FF 2 Fp 4 = A 4 = 4 = 1 & нон обоз о отн он отн
т о. и о ой + к мт и тн тн к я = =m um
+ и чт иная ви в вая *
в к чин и тие ня я кн вина но %
= =: = пин ин вн в т #5 ен ни т та =
+ 4 d кан и a ши a = a@ = =
т 4 ++ EU 4 #& + к та т a тн кн
: = = = =m я и A w
+ т и к т нов #4 = ни = m= ® = § PF # 4 кв кон ов шо + я в E = = =m
- = = = = =: + = = =m § p + #& +4 tb Fk a ок a w W = = = BE дн о во 4
* t = = = = = = = = = = x § + + + = mu
т и ха вв к ня ин ош я к = ков он кон о #% & + а на и к дна
и #4 F #* + к жа ноя ко =
+ #4 4 = = 1 да кн на я ня
= = = =: # F # 4 + ки ти тн в x = 4
т и ни = он к он = = % #4 #% ù = = x = = a + & = = = 4 # 1 = =m a sw nm
= =: и ви к т & F янв ни к нь
: т и = m= a = x #4 к ант" =
4 к = = ® = = x 4 & a =: = = FF =
= = A = HN = 4
4 ен он H я в HO FO = + X + AN
= = = A ON 4 +4
к = и кли не тов # 4 A + ss =m 4 FB F&F & EB 4 F 2 BB a BE § A § &
= = = & F ® ыы # 4 4 ыы = = m 4 # I
= = > a § + 1 # & a F¥ a ¢ я о к FF кн шт ши к я и # KN 4 w nm
4 о пин в 5 Аа ин я ха ¥ = > a 4 X 4
«+ « = = =: WwW =m a = BF F tt & отн = a
« = #4 # + + 1 + 4 ®m 1 = = ово =
« # = ®m = = § & & #4 = d * = + = = =
« =: & FB & FE тн ни ши и ян 1
+ # = =: = ® 4 ® = F # #F EE # 4 kk = ® = EB =m F FF Fa > ss = a ка
ml A Ad A AA de e O =& ACA ÓJ Le ll о =& A AD AA
nl — =& —& —А 4 PACA PI CI I — —& — =]
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-481 Page 51
=
bm,
item Part
No. No. Description Quantity
Figure 11-7. Generator (Fig 11-1 item 54)
1 049650 BRACKET, mig-brushholder KK
2 018614 BRUSHSET, (consisting of) ............ RR aa ea Le aan
3 *044 755 BRUSH, contact .............emeeresnicerareaveroarenarermore rene.
4 600270 HOLDER, brush ..............0000areereereraceorrnvorcreco, nara,
5 018865 CAP, brush holder .. 4 a a Le ea a aa 1 ea aa aa a Lee
6 013367 LABEL, warning moving parts etc .........222 20424040 a a eee sa a eee Ne
7 602243 WASHER, flat stl std.375 ......1 202001001144 4444 4 4 4 ee a 4 a ee 8 es a ae see ee
8 +130989 STATOR, generator ...........—.revererrrererer e eee a Rae
9 039207 BAFFLE, air-generator ..............——.rrexmevorrrrricereredrneere rene.
10 083751 ROTOR, gen (consisting of) ..............e. 2... 222.0. 00... arorerec.
11 024 617 - RING, retaining-external ...........ecec.e..ereaerrrere raros rare.
12 053390 “BEARING, ball .......... ee... 000. ..neeriearerecrerrereer rene,
13 083 748 -: FAN, rotor ...........em02earearorereÑrcr arar vere daaravero reordenar ae
14 117009 STATOR, excitor ........e._e.-.0esenederer event ene reneoreraddrr reserve,
15 049235 ENDBELL, generator ..........o___e_e_e—r-r-eoem0s0cirreodeneonrreveddmerama
16 086 853 SCREW, cap stl hexwhd sifikg .375-16X 1.00 ...............e reseca
Figure 11-7. Generator
"Recommended Spare Parts.
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
OM-481 Page 52
O TL a e CY PN) =& —& —® (д) A
- 50-134 503
Dia.
Mkgs.
Part
No.
Description
Optional Equipment
Quantity
E51
041 480
034 074
113 342
046 410
073 100
021 467
021 385
020 185
035 325
042 480
134 613
123 205
123 207
122 613
087 341
ETHER STARTING AID, (consisting of)
- STARTING AID KIT, diesel
- ADAPTER, atomizer
- ATOMIZER, .125 L elb orf
- TUBING, vinyl .375 (order by ft)
- SWITCH, tgl SPST MC 3A 250V (Fig 11-2)
- BOOT, tgl switch lever (Fig 11-2)
FITTING, pipe brs elb st 1/8NPT
= = = = = = mm 4 к к 4 + pF 3 4 BB a a EW A F 4 ин a2 E ® 4 * & HE 4 = 4 >
а оне mw & w 4 ® = a= = a mw a в аи ква т a mm =m m =m mE |W EN WW EN OW mw + mw m & =m
« # # | ово о о нон оли ош mE ок m= ин кн А в ов #% 4 4d F CT ss = § wT = ® + à
"= & # + ® & d = % 4 к тн mW ENE & mW mE & ¥ & 4 PF #% 4 % kK около ов оч ов он о >)^ FÜ mE = =m
If т аи ми тн нк ®m aA на ни * 4 w om om ®W om om EN EN ни ки в ява
"= = = = в я ® A =m EE нон ян ок mE = ua EB ¥ 4 # 4 uw + wm
яч т т че ви ни на ни ви и да т они ок ни ни ни кина на аа
= =: = = = § # & HU #5 +4 & он ти нон коня F 4 F 4 вояж он от он отн + & нд
- LABEL, ether starting air caution etc
COVER, locking nameplate (consisting of)
- COVER, top
- HINGE, cover front
- COVER, panel front
- BOLT, U st! .312-18
- BUMPER, door 1.000 OD x .750
= = = x = и x яч хи т на =m um
#¥ = + = = = = = x =
= = = 4 HE x & # # =
= + { # F ® vv a =» =
= 4 и ноя он ов нок о к ан он он ши нон ®% ¥ & # ® #% 4 #% 4 4 = = a FR EE E п в =
т о анна ва тен = mE m & EN 4 ни ти т ни ни ни я на в * 4% 4 * * 4 x
« = = = ав на = к в & я та ти нон кои > он Ан А EH & #4 & w= 4 5 1 = = w
и к ян ан к 5 d ++ 1 = 1 = ss 1 ss ss ss ss 1 = 4 & FF & F ww отн ож нот он ож киа
+ тва ты ти вн om m к и вая ян д Я хи т ни ни не ви жи ква 4 &
= К meh eh —] == — —
—
rm
3 A 4 A A A
OM-48 7 37. 53
te -
ha im
OPTIONS AND ACCESSORIES
AUXILIARY POWER
(#042 242) Factory Only
5KW, 240V three-phase reconnectabie
to 3KW, 120/240V single-phase power
available while welding. Designed
for heavy-duty, industrial, three-phase
grinders and simitar power tools.
LOCKUP PACKAGE
(#042 480 Factory)
(#042 266 Field)
A lockable, hinged, clear high
impact plastic panel covers controls.
(Padlock not included).
FA-4 FLAME ARRESTOR FUEL CAP
(#042 185)
STARTING AID KIT
(#041 480 Factory)
(#042 498 Field)
Ether type for cold weather starting.
SPARK ARRESTOR MUFFLER
(#042 184)
Mandatory when operating on
National Forest land. For other areas,
check your state and local laws.
CC-8 CANVAS COVER
(#042 483)
Protect the finish and extend the
service life of this product by using
our heavy-duty canvas cover. This
attractive blue cover is fire retardant
and mildew resistant.
Te -
im,
OPTIONS AND ACCESSORIES
3000-4 FOUR-WHEEL
TANDEM TRAILER
(#041 015)
The tandem axie design enables this
trailer to ride smoothly over rough
terrain. The unit is equipped with
fenders, lights, a leveling jack, 2 in.
(50 mm) ball hitch, and safety chains.
The two-wheel, self-actuating hydraulic
brake system operates automatically
as pressure is put against the tongue
of the trailer. Another feature is a
break-away device which would
automatically lock the brakes should
the trailer become loose. A hand-
operated parking brake is standard.
Specifications: |
Total Width: 72-1/4 in. (1.8 m)
Tread: 63 in. (1.6 m)
Length: 163-1/2 in. (4.2 m)
Height of Bed: 19 in. (483 mm)
Road Clearance: 10 in. (254 mm)
GVWR: 3000 ibs. (1360 kg)
Shipping Wt. 757 lbs. (343 kg)
TOOL BOX
(#040 638)
For use with four-wheel trailers.
Keeps tools handy. Sturdy steel
construction with hinged cover. 5 in.
(127 mm) divider in center of box.
Attachment hardware included.
Height 11 in. (280 mm), depth 10 in.
(254 mm), length 44 in. (1118 mm).
NO. 4WA WELDING ACCESSORIES
(#040 045)
35 ft. (10.7 m) No. 2/0 electrode cable
with electrode holder and lug; 30 fi.
(9 M) No. 2/0 work cable with lugs
attached; welding helmet; and wire
scratch brush. For high amperage
welding, larger cables, electrode
holder, and ground clamp are required.
NO. 84X FOUR-WHEEL
TANDEM TRAILER
(#042 150)
For off-the-road use only. The
tandem axle, torsion bar design
enables this trailer to ride smoothly
over rough terrain.
Note: Hitch must be ordered separately.
When ordering off-road trailers, the
purchase order must include the
statement, “For off-the-road use only.”
FENDER AND LIGHT KIT
(#042 198)
includes fenders, 12 Volt light set.
HITCHES
CLEVIS
(#042 151)
For use on No. 84X trailer.
Shipping weight 11 lbs. (5 kg)
CLEVIS
(Not for highway use)
(#041 726)
For use on EDT 2400-2 trailer.
Shipping weight 11 Ibs. (5 kg)
2 in. (50 mm) BALL
(4042 153)
For use on No. 84X trailer.
Shipping weight 5 Ibs. (2 kg)
2 in. (50 mm) BALL
(4041 724)
For use on EDT 2400-2 trailer.
Shipping weight 5 Ibs. (2 kg)
3 in. (76 mm) LUNETTE EYE
(#042 152)
For use on No. 84X trailer.
Shipping weight 9 ibs. (4 kg)
2-1/2 in. (64 mm) LUNETTE EYE
(#041 725)
For use on EDT 2400-2 trailer.
Shipping weight 9 Ibs. (4 kg)
3 in. (76 mm) LUNETTE EYE
(#041 628 Factory)
For use on 3000-4 trailer.
Shipping weight 9 Ibs. (4 kg)
REMOTE CONTROLS
RFC-14 FOOT CONTROL
(4129 339)
Foot current and contactor control.
20 ft. (6 m) cord and 14-pin
Ampheno! plug.
RHC-14 HAND CONTROL
(#129 340)
Remote hand current and contactor
control with 20 ft. (6 m) cord and
14-pin plug.
RMLS-14 SWITCH
(#129 337)
Momentary- and maintained-contact
rocker switch for contactor control.
Push forward for maintained contact
and backward for momentary
contact. Includes 20 ft. (6 m) cord
and 14-pin Amphenol plug.
FTC-14 REMOTE CONTACTOR
AND CURRENT CONTROL
(#129 338)
Fastens to TIG torch handle.
Includes 28 ft. (8.5 m) cord and
14-pin Amphenol plug.
EXTENSION CORDS FOR 14-PIN
REMOTE CONTROLS
10ft. (3m) (#122 972)
25 ft. (7.6 m) (#122 973)
50 ft. (15.2 m) (#122 974)
75 ft. (22.8 m) (#122 975)
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